Method of using lockout features for surgical stapler cartridge

ABSTRACT

A surgical instrument comprises a body, shaft, and end effector. The shaft couples the end effector and body together. The end effector comprises an anvil and lower jaw configured to receive a surgical staple cartridge. The anvil is configured to pivot toward and away from the staple cartridge and lower jaw. The shaft assembly comprises a knife member configured to longitudinally translate to thereby substantially simultaneously cut clamped tissue and staple the severed tissue. The end effector may comprise lockout features configure to prevent longitudinal translation of the knife member. The end effector or staple cartridge may comprise lockout bypass features configured to prevent lockout of the knife member. These lockout bypass features may operate to permit longitudinal translation of the knife member once or multiple times. The end effector may comprise features configured to ensure proper alignment of the anvil relative to the staple cartridge.

BACKGROUND

In some settings, endoscopic surgical instruments may be preferred overtraditional open surgical devices since a smaller incision may reducethe post-operative recovery time and complications. Consequently, someendoscopic surgical instruments may be suitable for placement of adistal end effector at a desired surgical site through the cannula of atrocar. These distal end effectors may engage tissue in a number of waysto achieve a diagnostic or therapeutic effect (e.g., endocutter,grasper, cutter, stapler, clip applier, access device, drug/gene therapydelivery device, and energy delivery device using ultrasonic vibration,RF, laser, etc.). Endoscopic surgical instruments may include a shaftbetween the end effector and a handle portion, which is manipulated bythe clinician. Such a shaft may enable insertion to a desired depth androtation about the longitudinal axis of the shaft, thereby facilitatingpositioning of the end effector within the patient. Positioning of anend effector may be further facilitated through inclusion of one or morearticulation joints or features, enabling the end effector to beselectively articulated or otherwise deflected relative to thelongitudinal axis of the shaft.

Examples of endoscopic surgical instruments include surgical staplers.Some such staplers are operable to clamp down on layers of tissue, cutthrough the clamped layers of tissue, and drive staples through thelayers of tissue to substantially seal the severed layers of tissuetogether near the severed ends of the tissue layers. Merely exemplarysurgical staplers are disclosed in U.S. Pat. No. 4,805,823, entitled“Pocket Configuration for Internal Organ Staplers,” issued Feb. 21,1989; U.S. Pat. No. 5,415,334, entitled “Surgical Stapler and StapleCartridge,” issued May 16, 1995; U.S. Pat. No. 5,465,895, entitled“Surgical Stapler Instrument,” issued Nov. 14, 1995; U.S. Pat. No.5,597,107, entitled “Surgical Stapler Instrument,” issued Jan. 28, 1997;U.S. Pat. No. 5,632,432, entitled “Surgical Instrument,” issued May 27,1997; U.S. Pat. No. 5,673,840, entitled “Surgical Instrument,” issuedOct. 7, 1997; U.S. Pat. No. 5,704,534, entitled “Articulation Assemblyfor Surgical Instruments,” issued Jan. 6, 1998; U.S. Pat. No. 5,814,055,entitled “Surgical Clamping Mechanism,” issued Sep. 29, 1998; U.S. Pat.No. 6,978,921, entitled “Surgical Stapling Instrument Incorporating anE-Beam Firing Mechanism,” issued Dec. 27, 2005; U.S. Pat. No. 7,000,818,entitled “Surgical Stapling Instrument Having Separate Distinct Closingand Firing Systems,” issued Feb. 21, 2006; U.S. Pat. No. 7,143,923,entitled “Surgical Stapling Instrument Having a Firing Lockout for anUnclosed Anvil,” issued Dec. 5, 2006; U.S. Pat. No. 7,303,108, entitled“Surgical Stapling Instrument Incorporating a Multi-Stroke FiringMechanism with a Flexible Rack,” issued Dec. 4, 2007; U.S. Pat. No.7,367,485, entitled “Surgical Stapling Instrument Incorporating aMultistroke Firing Mechanism Having a Rotary Transmission,” issued May6, 2008; U.S. Pat. No. 7,380,695, entitled “Surgical Stapling InstrumentHaving a Single Lockout Mechanism for Prevention of Firing,” issued Jun.3, 2008; U.S. Pat. No. 7,380,696, entitled “Articulating SurgicalStapling Instrument Incorporating a Two-Piece E-Beam Firing Mechanism,”issued Jun. 3, 2008; U.S. Pat. No. 7,404,508, entitled “SurgicalStapling and Cutting Device,” issued Jul. 29, 2008; U.S. Pat. No.7,434,715, entitled “Surgical Stapling Instrument Having MultistrokeFiring with Opening Lockout,” issued Oct. 14, 2008; U.S. Pat. No.7,721,930, entitled “Disposable Cartridge with Adhesive for Use with aStapling Device,” issued May 25, 2010; U.S. Pat. No. 8,408,439, entitled“Surgical Stapling Instrument with An Articulatable End Effector,”issued Apr. 2, 2013; and U.S. Pat. No. 8,453,914, entitled “Motor-DrivenSurgical Cutting Instrument with Electric Actuator Directional ControlAssembly,” issued Jun. 4, 2013. The disclosure of each of theabove-cited U.S. patents is incorporated by reference herein.

While the surgical staplers referred to above are described as beingused in endoscopic procedures, it should be understood that suchsurgical staplers may also be used in open procedures and/or othernon-endoscopic procedures. By way of example only, a surgical staplermay be inserted through a thoracotomy, and thereby between a patient'sribs, to reach one or more organs in a thoracic surgical procedure thatdoes not use a trocar as a conduit for the stapler. Such procedures mayinclude the use of the stapler to cut and close a vessel leading to alung. For instance, the vessels leading to an organ may be severed andclosed by a stapler before removal of the organ from the thoraciccavity. Of course, surgical staplers may be used in various othersettings and procedures.

Examples of surgical staplers that may be particularly suited or usethrough a thoracotomy are disclosed in U.S. patent application Ser. No.13/780,067, entitled “Surgical Instrument End Effector ArticulationDrive with Pinion and Opposing Racks,” filed Feb. 28, 2013; U.S. patentapplication Ser. No. 13/780,082, entitled “Lockout Feature for MovableCutting Member of Surgical Instrument,” filed Feb. 28, 2013; U.S. patentapplication Ser. No. 13/780,106, entitled “Integrated Tissue Positioningand Jaw Alignment Features for Surgical Stapler,” filed Feb. 28, 2013;U.S. patent application Ser. No. 13/780,120, entitled “Jaw ClosureFeature for End Effector of Surgical Instrument,” filed Feb. 28, 2013;U.S. patent application Ser. No. 13/780,162, entitled “SurgicalInstrument with Articulation Lock having a Detenting Binary Spring,”filed Feb. 28, 2013; U.S. patent application Ser. No. 13/780,171,entitled “Distal Tip Features for End Effector of Surgical Instrument,”filed Feb. 28, 2013; U.S. patent application Ser. No. 13/780,379,entitled “Staple Forming Features for Surgical Stapling Instrument,”filed Feb. 28, 2013; U.S. patent application Ser. No. 13/780,402,entitled “Surgical Instrument with Multi-Diameter Shaft,” filed Feb. 28,2013; and U.S. patent application Ser. No. 13/780,417, entitled“Installation Features for Surgical Instrument End Effector Cartridge,”filed Feb. 28, 2013. The disclosure of each of the above-cited U.S.patent applications is incorporated by reference herein.

While various kinds of surgical stapling instruments and associatedcomponents have been made and used, it is believed that no one prior tothe inventor(s) has made or used the invention described in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention,and, together with the general description of the invention given above,and the detailed description of the embodiments given below, serve toexplain the principles of the present invention.

FIG. 1 depicts a perspective view of an exemplary articulating surgicalstapling instrument;

FIG. 2 depicts a side elevational view of the instrument of FIG. 1;

FIG. 3 depicts a perspective view of an end effector of the instrumentof FIG. 1, with the end effector in a closed configuration;

FIG. 4 depicts a perspective view of the end effector of FIG. 3, withthe end effector in an open configuration;

FIG. 5 depicts an exploded perspective view of the end effector of FIG.3;

FIG. 6 depicts a cross-sectional end view of the end effector of FIG. 3,taken along line 6-6 of FIG. 4;

FIG. 7A depicts a cross-sectional side view of the end effector of FIG.3, taken along line 7-7 of FIG. 4, with the firing beam in a proximalposition;

FIG. 7B depicts a cross-sectional side view of the end effector of FIG.3, taken along line 7-7 of FIG. 4, with the firing beam in a distalposition;

FIG. 8 depicts a perspective view of the end effector of FIG. 3,positioned at tissue and having been actuated once in the tissue;

FIG. 9 depicts a schematic view of an exemplary control circuit for usein the instrument of FIG. 1;

FIG. 10 depicts a perspective view of the handle assembly of theinstrument of FIG. 1, with a housing half and some internal componentsremoved;

FIG. 11 depicts a perspective view of drive assembly components from thehandle assembly of FIG. 10;

FIG. 12 depicts a perspective view of an elongate member from the driveassembly of FIG. 11, coupled with the firing beam;

FIG. 13 depicts an exploded view of an exemplary alternative endeffector that may be incorporated into the instrument of FIG. 1;

FIG. 14 depicts a perspective view of an exemplary blade of the endeffector of FIG. 13;

FIG. 15 depicts a side view of the blade of FIG. 14;

FIG. 16 depicts a perspective view of an exemplary stationary jaw of theend effector of FIG. 13;

FIG. 17 depicts an end view of the blade of FIG. 14 positioned in a slotof the stationary jaw of FIG. 16;

FIG. 18 depicts a perspective view of an exemplary lockout feature ofthe end effector of FIG. 13;

FIG. 19 depicts a cross sectional view of the lockout of feature of FIG.18 taken along line 19-19 of FIG. 18;

FIG. 20 depicts a perspective view of an exemplary spring of the endeffector of FIG. 13;

FIG. 21 depicts a cross sectional view of the spring of FIG. 20 takenalong line 21-21 of FIG. 20;

FIG. 22 depicts a perspective view of an exemplary closure ring of theend effector of FIG. 13;

FIG. 23A depicts a side cross sectional view of the end effector of FIG.13 in an initial position;

FIG. 23B depicts a side cross sectional view of the end effector of FIG.13 in a lockout position;

FIG. 24A depicts a bottom perspective view of the end effector of FIG.13 in the initial position;

FIG. 24B depicts a bottom perspective view of the end effector of FIG.13 in the lockout position;

FIG. 25A depicts a side cross sectional view of the end effector of FIG.13 in the initial position with a loaded cartridge;

FIG. 25B depicts a side cross sectional view of the end effector of FIG.13 in a first partially fired position with a loaded cartridge;

FIG. 25C depicts a side cross sectional view of the end effector of FIG.13 in a second partially fired position with a loaded cartridge;

FIG. 25D depicts a side cross sectional view of the end effector of FIG.13 in a third partially fired position with a loaded cartridge;

FIG. 25E depicts a side cross sectional view of the end effector of FIG.13 in a fourth partially fired position with a loaded cartridge;

FIG. 25F depicts a side cross sectional view of the end effector of FIG.13 in a fifth partially fired position with a loaded cartridge;

FIG. 26 depicts a perspective view of the proximal end of an exemplaryalternative cartridge that may be incorporated into the end effector ofFIG. 13;

FIG. 27 depicts a cross-sectional perspective view of the proximal endof the cartridge of FIG. 26;

FIG. 28 depicts a cross-sectional top view of the proximal end of thecartridge of FIG. 26;

FIG. 29A depicts a perspective view of the proximal end of the cartridgeof FIG. 26 engaged with the end effector of FIG. 13, with a resilienttab of the cartridge in a first rotational position, with a sled of thecartridge in a first longitudinal position, and with the knife of theend effector in a first longitudinal position;

FIG. 29B depicts a perspective view of the proximal end of the cartridgeof FIG. 26 engaged with the end effector of FIG. 13, with the resilienttab of the cartridge in the first rotational position, with the sled ofthe cartridge in the first longitudinal position, and with the knife ofthe end effector moved into a second longitudinal position;

FIG. 29C depicts a perspective view of the proximal end of the cartridgeof FIG. 26 engaged with the end effector of FIG. 13, with the resilienttab of the cartridge in the first rotational position, with the sled ofthe cartridge moved into a second longitudinal position by movement ofthe knife of the end effector into a third longitudinal position;

FIG. 29D depicts a perspective view of the proximal end of the cartridgeof FIG. 26 engaged with the end effector of FIG. 13, with the resilienttab of the cartridge moved into a second rotational position by movementof the sled of the cartridge into the second longitudinal position andby movement of the knife of the end effector moved back into the firstlongitudinal position;

FIG. 30 depicts a perspective view of the proximal end of anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 13;

FIG. 31 depicts a cross-sectional side view of the proximal end of thecartridge of FIG. 30;

FIG. 32A depicts a cross-sectional view of the proximal end of thecartridge of FIG. 30 disposed within the end effector of FIG. 13, with asled of the cartridge in a first longitudinal position and with a knifeof the end effector in a first longitudinal position;

FIG. 32B depicts a cross-sectional view of the proximal end of thecartridge of FIG. 30 disposed within the end effector of FIG. 13, withthe sled of the cartridge in the first longitudinal position and withthe knife of the end effector moved into a second longitudinal position;

FIG. 32C depicts a cross-sectional view of the proximal end of thecartridge of FIG. 30 disposed within the end effector of FIG. 13, withthe sled of the cartridge moved into a second longitudinal position bymovement of the knife of the end effector into a third longitudinalposition, with the knife breaking through the breakaway feature of thecartridge;

FIG. 32D depicts a cross-sectional view of the proximal end of thecartridge of FIG. 30 disposed within the end effector of FIG. 13, withthe knife of the end effector moved back into the first longitudinalposition and with the breakaway feature no longer present;

FIG. 32E depicts a cross-sectional view of the proximal end of thecartridge of FIG. 30 disposed within the end effector of FIG. 13, withthe knife of the end effector moved into a lockout position upon beingmoved toward the second longitudinal position;

FIG. 33 depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 13;

FIG. 34 depicts a cross-sectional side view of the proximal end of thecartridge of FIG. 33;

FIG. 35 depicts a cross-sectional perspective view of the proximal endof the cartridge of FIG. 33;

FIG. 36A depicts a cross-sectional view of the proximal end of thecartridge of FIG. 33 disposed within the end effector of FIG. 13, with asled of the cartridge in a first longitudinal position and with a knifeof the end effector in a first longitudinal position;

FIG. 36B depicts a cross-sectional view of the proximal end of thecartridge of FIG. 33 disposed within the end effector of FIG. 13, withthe sled of the cartridge in the first longitudinal position and withthe knife of the end effector moved into a second longitudinal position;

FIG. 36C depicts a cross-sectional view of the proximal end of thecartridge of FIG. 33 disposed within the end effector of FIG. 13, withthe sled of the cartridge moved into a second longitudinal position bymovement of the knife of the end effector into a third longitudinalposition, with the knife breaking through the breakaway feature of thecartridge;

FIG. 36D depicts a cross-sectional view of the proximal end of thecartridge of FIG. 33 disposed within the end effector of FIG. 13, withthe knife of the end effector moved back into the first longitudinalposition and with the breakaway feature no longer present;

FIG. 36E depicts a cross-sectional view of the proximal end of thecartridge of FIG. 33 disposed within the end effector of FIG. 13, withthe knife of the end effector moved into a lockout position upon beingmoved toward the second longitudinal position;

FIG. 37 depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 13;

FIG. 38 depicts a top view of the proximal end of the cartridge of FIG.37;

FIG. 39 depicts a cross-sectional side view of the proximal end of thecartridge of FIG. 37;

FIG. 40 depicts a cross-sectional perspective view of the proximal endof the cartridge of FIG. 37;

FIG. 41A depicts a cross-sectional view of the proximal end of thecartridge of FIG. 37 disposed within the end effector of FIG. 13, withthe breakaway feature in a first rotational position, with a sled of thecartridge in a first longitudinal position, and with a knife of the endeffector in a first longitudinal position;

FIG. 41B depicts a cross-sectional view of the proximal end of thecartridge of FIG. 37 disposed within the end effector of FIG. 13, withthe breakaway feature in the first rotational position, with the sled ofthe cartridge in the first longitudinal position, and with the knife ofthe end effector moved into a second longitudinal position;

FIG. 41C depicts a cross-sectional view of the proximal end of thecartridge of FIG. 37 disposed within the end effector of FIG. 13, withthe breakaway feature moved into a second rotational position and withthe sled of the cartridge moved into a second longitudinal position bothby movement of the knife of the end effector into a third longitudinalposition;

FIG. 41D depicts a cross-sectional view of the proximal end of thecartridge of FIG. 37 disposed within the end effector of FIG. 13, withthe breakaway feature in the second rotational position and with theknife of the end effector moved back into the first longitudinalposition;

FIG. 41E depicts a cross-sectional view of the proximal end of thecartridge of FIG. 37 disposed within the end effector of FIG. 13, withthe knife of the end effector moved into a lockout position upon beingmoved toward the second longitudinal position;

FIG. 42 depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 13;

FIG. 43 depicts a top view of the proximal end of the cartridge of FIG.42;

FIG. 44A depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 13;

FIG. 44B depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge with the alternative pair of guide finsmoved into an open position;

FIG. 45A depicts a top view of the proximal end of the cartridge of FIG.44A with the guide fins in the closed position;

FIG. 45B depicts a top view of the proximal end of the cartridge of FIG.44A with the guide fins moved into the open position;

FIG. 46 depicts a cross-sectional side view of the proximal end of thecartridge of FIG. 44A disposed within the end effector of FIG. 13;

FIG. 47 depicts a perspective view of the proximal end of an exemplarycartridge tray that may be incorporated into a cartridge of the endeffector of FIG. 13;

FIG. 48 depicts a top view of the proximal end of the cartridge tray ofFIG. 47;

FIG. 49A depicts a cross-sectional perspective view of the proximal endof the cartridge tray of FIG. 47 with components of the end effector ofFIG. 13, with a knife of the end effector in a first longitudinalposition;

FIG. 49B depicts a cross-sectional perspective view of the proximal endof the cartridge tray of FIG. 47 with components of the end effector ofFIG. 13, with the knife of the end effector moved into a secondlongitudinal position;

FIG. 50 depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 13;

FIG. 51 depicts a top view of the proximal end of the cartridge of FIG.50;

FIG. 52A depicts a cross-sectional view of the proximal end of thecartridge of FIG. 50 disposed within the end effector of FIG. 13, with aknife of the end effector in a first longitudinal position;

FIG. 52B depicts a cross-sectional view of the proximal end of thecartridge of FIG. 50 disposed within the end effector of FIG. 13, withthe knife of the end effector moved into a second longitudinal position;

FIG. 53 depicts a perspective view of yet another exemplary alternativecartridge that may be incorporated into the end effector of FIG. 13;

FIG. 54 depicts a side view of the cartridge of FIG. 53;

FIG. 55 depicts a top view of the proximal end of the cartridge of FIG.53;

FIG. 56 depicts a cross-sectional view of the proximal end of thecartridge of FIG. 53 disposed within the end effector of FIG. 13;

FIG. 57 depicts a perspective view of an exemplary tab insert;

FIG. 58A depicts a perspective view of the end effector of FIG. 13, withthe tab insert of FIG. 57 positioned to couple with the end effector;

FIG. 58B depicts a perspective view of the end effector of FIG. 13, withthe tab insert of FIG. 57 positioned within the end effector;

FIG. 59A depicts a cross-sectional side view of the end effector of FIG.13, with the tab insert of FIG. 57 positioned to couple with the endeffector;

FIG. 59B depicts a cross-sectional side view of the end effector of FIG.13, with the tab insert of FIG. 57 positioned within the end effector;

FIG. 60 depicts a perspective view of an exemplary ramp insert;

FIG. 61 depicts a cross-sectional side view of the end effector of FIG.13 with the ramp insert of FIG. 60 positioned within the end effector;

FIG. 62 depicts a perspective view of yet another exemplary alternativecartridge that may be incorporated into the end effector of FIG. 13;

FIG. 63 depicts a side view of the proximal end of the cartridge of FIG.62;

FIG. 64A depicts a cross-sectional view of the proximal end of thecartridge of FIG. 62 disposed within the end effector of FIG. 13, with aknife of the end effector in a first longitudinal position;

FIG. 64B depicts a cross-sectional view of the proximal end of thecartridge of FIG. 62 disposed within the end effector of FIG. 13, withthe knife of the end effector moved into a second longitudinal position;

FIG. 65 depicts a perspective view of an exemplary alternative anvilthat may be incorporated into the end effector of FIG. 3;

FIG. 66 depicts a cross-sectional side view of the anvil of FIG. 65;

FIG. 67A depicts a partial cross-sectional side elevational view of theend effector of FIG. 3 with the anvil of FIG. 65 in a first rotationalposition;

FIG. 67B depicts a partial cross-sectional side elevational view of theend effector of FIG. 3 with the anvil of FIG. 65 moved into a secondrotational position;

FIG. 68 depicts a perspective view of an underside region of anotherexemplary alternative anvil that may be incorporated into the endeffector of FIG. 3;

FIG. 69 depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 3;

FIG. 70A depicts a cross-sectional side view of the end effector of FIG.3 with the cartridge of FIG. 69 in a first longitudinal position andwith the anvil of FIG. 68 in a first rotational position;

FIG. 70B depicts a cross-sectional side view of the end effector of FIG.3 with the cartridge of FIG. 69 moved into a second longitudinalposition by movement of the anvil of FIG. 68 into a second rotationalposition;

FIG. 71 depicts a cross-sectional perspective view of the end effectorof FIG. 3 with the cartridge of FIG. 68 engaged with the anvil of FIG.69;

FIG. 72 depicts a perspective view of yet another exemplary alternativecartridge that may be incorporated into the end effector of FIG. 3;

FIG. 73 depicts a top view of the proximal end of the cartridge of FIG.72;

FIG. 74 depicts a side view of the cartridge of FIG. 72;

FIG. 75 depicts a perspective view of an exemplary lower jaw that may beincorporated into the end effector of FIG. 3;

FIG. 76 depicts a side view of the lower jaw of FIG. 75;

FIG. 77 depicts a perspective view of the proximal end of the cartridgeof FIG. 72 engaged with the lower jaw of FIG. 75;

FIG. 78 depicts a perspective view of yet another exemplary alternativecartridge that may be incorporated into the end effector of FIG. 3;

FIG. 79 depicts a side view of the proximal end of the cartridge of FIG.78;

FIG. 80 depicts a top view of the proximal end of the cartridge of FIG.78;

FIG. 81 depicts a perspective view of an exemplary alternative lower jawthat may be incorporated into the end effector of FIG. 3;

FIG. 82 depicts a rear view of the lower jaw of FIG. 81;

FIG. 83 depicts a top view of the proximal end of the lower jaw of FIG.81;

FIG. 84 depicts a perspective view of the proximal end of the cartridgeof FIG. 78 engaged with the proximal end of the lower jaw of FIG. 81;

FIG. 85 depicts a top view of the proximal end of the cartridge of FIG.78 engaged with the proximal end of the lower jaw of FIG. 81;

FIG. 86 depicts a cross-sectional perspective view of the proximal endof the cartridge of FIG. 78 engaged with the proximal end of the lowerjaw of FIG. 81;

FIG. 87 depicts a perspective view of an exemplary sled;

FIG. 88 depicts a side view of the sled of FIG. 87;

FIG. 89 depicts a top view of the self of FIG. 87;

FIG. 90 depicts a perspective view of the sled of FIG. 87 positionedwithin yet another exemplary alternative cartridge that may beincorporated into the end effector of FIG. 13;

FIG. 91 depicts a side view of the sled of FIG. 87 positioned within theproximal end of the cartridge of FIG. 90;

FIG. 92 depicts a top view of the sled of FIG. 87 positioned within theproximal end of the cartridge of FIG. 90;

FIG. 93 depicts a perspective view of the sled of FIG. 87 and thecartridge of FIG. 90 engaged with the lower jaw of FIG. 81;

FIG. 94 depicts a top view of the sled of FIG. 87 extending from theproximal end of the cartridge of FIG. 78 and engaged with the proximalend of the lower jaw of FIG. 81;

FIG. 95 depicts a cross-sectional perspective view of the sled of FIG.87 extending from the proximal end of the cartridge of FIG. 78 andengaged with the proximal end of the lower jaw of FIG. 81;

FIG. 96 depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 13;

FIG. 97 depicts a perspective view of the proximal end of the cartridgeof FIG. 96 engaged with the proximal end of a lower jaw of the endeffector of FIG. 3;

FIG. 98 depicts a rear view of the cartridge of FIG. 96 engaged with thelower jaw of FIG. 97;

FIG. 99 depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 13;

FIG. 100 depicts a side view of the proximal end of the cartridge ofFIG. 99;

FIG. 101 depicts a cross-sectional side view of the proximal end of thecartridge of FIG. 99 engaged with the end effector of FIG. 13;

FIG. 102 depicts a perspective view of the proximal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 13;

FIG. 103 depicts a side view of the proximal end of the cartridge ofFIG. 102;

FIG. 104 depicts a perspective view of the proximal end of the cartridgeof FIG. 102 engaged with the end effector of FIG. 13;

FIG. 105 depicts a cross-sectional perspective view of the proximal endof the cartridge of FIG. 102 engaged with the end effector of FIG. 13;

FIG. 106 depicts a cross-sectional side view of the proximal end of thecartridge of FIG. 102 engaged with the end effector of FIG. 13;

FIG. 107 depicts a perspective view of the distal end of an exemplaryalternative cartridge that may be incorporated into the end effector ofFIG. 3;

FIG. 108 depicts a perspective view of the distal end of anotherexemplary alternative anvil that may be incorporated into the endeffector of FIG. 3;

FIG. 109 depicts a cross-sectional side view of the distal end of thecartridge of FIG. 107 engaged with the distal end of the anvil of FIG.108;

FIG. 110 depicts a perspective view of the distal end of anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 3;

FIG. 111 depicts a side view of the distal end of the cartridge of FIG.110;

FIG. 112 depicts a perspective view of the distal end of yet anotherexemplary alternative anvil that may be incorporated into the endeffector of FIG. 3;

FIG. 113 depicts a cross-sectional side view of the distal end of thecartridge of FIG. 110 engaged with the distal end of the anvil of FIG.112;

FIG. 114 depicts a perspective view of the distal end of yet anotherexemplary alternative cartridge that may be incorporated into the endeffector of FIG. 3;

FIG. 115 depicts a side view of the distal end of the cartridge of FIG.114;

FIG. 116 depicts a perspective view of the distal end of yet anotherexemplary alternative anvil that may be incorporated into the endeffector of FIG. 3;

FIG. 117 depicts a cross-sectional side view of the distal end of thecartridge of FIG. 114 engaged with the distal end of the anvil of FIG.116;

FIG. 118 depicts a side elevation view of an exemplary alternativesurgical stapling instrument;

FIG. 119 depicts a cross-sectional side view of an end effector of theinstrument of FIG. 118;

FIG. 120 depicts a side elevation view of a firing bar of the surgicalinstrument of FIG. 118;

FIG. 121 depicts a front elevational view of the firing bar of FIG. 120;

FIG. 122 depicts a cross-sectional side view of the end effector of FIG.119 in a partially closed but unclamped position gripping tissue;

FIG. 123 depicts a side view of the surgical stapling instrument of FIG.118, with the end effector in the closed position;

FIG. 124 depicts a cross-sectional side view of the end effector of FIG.119 in the closed position with tissue properly compressed;

FIG. 125 depicts a side view of the surgical stapling instrument of FIG.118 in a partially fired position;

FIG. 126 depicts a cross-sectional side view of the end effector of FIG.119 in the partially fired position;

FIG. 127 depicts a side view of the surgical stapling instrument of FIG.118 in a fully fired position;

FIG. 128 depicts a cross-sectional side view of the end effector of FIG.119 in the fully fired position;

FIG. 129 depicts a perspective view of an exemplary alternativecartridge tray that may be incorporated into the cartridge of the endeffector of FIG. 13;

FIG. 130 depicts a detailed perspective view of the proximal end of thecartridge tray of FIG. 129;

FIG. 131 depicts a rear view of the cartridge tray of FIG. 129;

FIG. 132 depicts a perspective view of yet another exemplary cartridgehaving the cartridge tray of FIG. 129;

FIG. 133 depicts a perspective view of the proximal end of the cartridgeof FIG. 132;

FIG. 134 depicts a side view of the firing bar of FIG. 120 contactingthe proximal end of the cartridge tray of FIG. 129;

FIG. 135 depicts a perspective view of an exemplary alternative knifemember that may be incorporated into an exemplary alternative endeffector for the instrument of FIG. 1;

FIG. 136 depicts a side elevational view of the knife member of FIG.135;

FIG. 137 depicts a perspective view showing the underside of anexemplary alternative lower jaw that may be combined with the knifemember of FIG. 135 in an exemplary alternative end effector for theinstrument of FIG. 1;

FIG. 138 depicts a cross-sectional side view of an exemplary alternativeend effector incorporating the knife member of FIG. 135 and the lowerjaw of FIG. 137, with the knife member in a proximal position; and

FIG. 139 depicts a cross-sectional side view of the end effector of FIG.138, with the knife member in a locked out position.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the invention may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presentinvention, and together with the description serve to explain theprinciples of the invention; it being understood, however, that thisinvention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention shouldnot be used to limit the scope of the present invention. Other examples,features, aspects, embodiments, and advantages of the invention willbecome apparent to those skilled in the art from the followingdescription, which is by way of illustration, one of the best modescontemplated for carrying out the invention. As will be realized, theinvention is capable of other different and obvious aspects, all withoutdeparting from the invention. Accordingly, the drawings and descriptionsshould be regarded as illustrative in nature and not restrictive.

I. Exemplary Surgical Stapler

FIG. 1 depicts an exemplary surgical stapling and cutting instrument(10) that includes a handle assembly (20), a shaft assembly (30), and anend effector (40). End effector (40) and the distal portion of shaftassembly (30) are sized for insertion, in a nonarticulated state asdepicted in FIG. 1, through a trocar cannula to a surgical site in apatient for performing a surgical procedure. By way of example only,such a trocar may be inserted in a patient's abdomen, between two of thepatient's ribs, or elsewhere. In some settings, instrument (10) is usedwithout a trocar. For instance, end effector (40) and the distal portionof shaft assembly (30) may be inserted directly through a thoracotomy orother type of incision. It should be understood that terms such as“proximal” and “distal” are used herein with reference to a cliniciangripping handle assembly (20) of instrument (10). Thus, end effector(40) is distal with respect to the more proximal handle assembly (20).It will be further appreciated that for convenience and clarity, spatialterms such as “vertical” and “horizontal” are used herein with respectto the drawings. However, surgical instruments are used in manyorientations and positions, and these terms are not intended to belimiting and absolute.

A. Exemplary Handle Assembly and Shaft Assembly

As shown in FIGS. 1-2, handle assembly (20) of the present examplecomprises pistol grip (22), a closure trigger (24), and a firing trigger(26). Each trigger (24, 26) is selectively pivotable toward and awayfrom pistol grip (22) as will be described in greater detail below.Handle assembly (20) further includes an anvil release button (25), afiring beam reverse switch (27), and a removable battery pack (28).These components will also be described in greater detail below. Ofcourse, handle assembly (20) may have a variety of other components,features, and operabilities, in addition to or in lieu of any of thosenoted above. Other suitable configurations for handle assembly (20) willbe apparent to those of ordinary skill in the art in view of theteachings herein.

As shown in FIGS. 1-3, shaft assembly (30) of the present examplecomprises an outer closure tube (32), an articulation section (34), anda closure ring (36), which is further coupled with end effector (40).Closure tube (32) extends along the length of shaft assembly (30).Closure ring (36) is positioned distal to articulation section (34).Closure tube (32) and closure ring (36) are configured to translatelongitudinally relative to handle assembly (20). Longitudinaltranslation of closure tube (32) is communicated to closure ring (36)via articulation section (34). Exemplary features that may be used toprovide longitudinal translation of closure tube (32) and closure ring(36) will be described in greater detail below.

Articulation section (34) is operable to laterally deflect closure ring(36) and end effector (40) laterally away from the longitudinal axis(LA) of shaft assembly (30) at a desired angle (a). End effector (40)may thereby reach behind an organ or approach tissue from a desiredangle or for other reasons. In some versions, articulation section (34)enables deflection of end effector (40) along a single plane. In someother versions, articulation section (34) enables deflection of endeffector along more than one plane. In the present example, articulationis controlled through an articulation control knob (35) which is locatedat the proximal end of shaft assembly (30). Knob (35) is rotatable aboutan axis that is perpendicular to the longitudinal axis (LA) of shaftassembly (30). Closure ring (36) and end effector (40) pivot about anaxis that is perpendicular to the longitudinal axis (LA) of shaftassembly (30) in response to rotation of knob (35). By way of exampleonly, rotation of knob (35) clockwise may cause corresponding clockwisepivoting of closure ring (36) and end effector (40) at articulationsection (34). Articulation section (34) is configured to communicatelongitudinal translation of closure tube (32) to closure ring (36),regardless of whether articulation section (34) is in a straightconfiguration or an articulated configuration.

In some versions, articulation section (34) and/or articulation controlknob (35) are/is constructed and operable in accordance with at leastsome of the teachings of U.S. patent application Ser. No. 13/780,067,entitled “Surgical Instrument End Effector Articulation Drive withPinion and Opposing Racks,” filed Feb. 28, 2013, the disclosure of whichis incorporated by reference herein. Articulation section (34) may alsobe constructed and operable in accordance with at least some of theteachings of U.S. Pat. App. No. [Attorney Docket NumberEND7429USNP.0614273], entitled “Articulation Drive Features for SurgicalStapler,” filed on even date herewith, the disclosure of which isincorporated by reference herein; and/or U.S. Pat. App. No. [AttorneyDocket Number END7431USNP.0614277], entitled “Method of UnlockingArticulation Joint in Surgical Stapler,” filed on even date herewith,the disclosure of which is incorporated by reference herein. Othersuitable forms that articulation section (34) and articulation knob (35)may take will be apparent to those of ordinary skill in the art in viewof the teachings herein.

As shown in FIGS. 1-2, shaft assembly (30) of the present examplefurther includes a rotation knob (31). Rotation knob (31) is operable torotate the entire shaft assembly (30) and end effector (40) relative tohandle assembly (20) about the longitudinal axis (LA) of shaft assembly(30). In some versions, rotation knob (31) is operable to selectivelylock the angular position of shaft assembly (30) and end effector (40)relative to handle assembly (20) about the longitudinal axis (LA) ofshaft assembly (30). For instance, rotation knob (31) may betranslatable between a first longitudinal position, in which shaftassembly (30) and end effector (40) are rotatable relative to handleassembly (20) about the longitudinal axis (LA) of shaft assembly (30);and a second longitudinal position, in which shaft assembly (30) and endeffector (40) are not rotatable relative to handle assembly (20) aboutthe longitudinal axis (LA) of shaft assembly (30). Of course, shaftassembly (30) may have a variety of other components, features, andoperabilities, in addition to or in lieu of any of those noted above. Byway of example only, at least part of shaft assembly (30) is constructedin accordance with at least some of the teachings of U.S. patentapplication Ser. No. 13/780,402, entitled “Surgical Instrument withMulti-Diameter Shaft,” filed Feb. 28, 2013, the disclosure of which isincorporated by reference herein. Other suitable configurations forshaft assembly (30) will be apparent to those of ordinary skill in theart in view of the teachings herein.

B. Exemplary End Effector

As also shown in FIGS. 1-3, end effector (40) of the present exampleincludes a lower jaw (50) and a pivotable anvil (60). Anvil (60)includes a pair of integral, outwardly extending pins (66) that aredisposed in corresponding curved slots (54) of lower jaw (50). Pins (66)and slots (54) are shown in FIG. 5. Anvil (60) is pivotable toward andaway from lower jaw (50) between an open position (shown in FIGS. 2 and4) and a closed position (shown in FIGS. 1, 3, and 7A-7B). Use of theterm “pivotable” (and similar terms with “pivot” as a base) should notbe read as necessarily requiring pivotal movement about a fixed axis.For instance, in the present example, anvil (60) pivots about an axisthat is defined by pins (66), which slide along curved slots (54) oflower jaw (50) as anvil (60) moves toward lower jaw (50). In suchversions, the pivot axis translates along the path defined by slots (54)while anvil (60) simultaneously pivots about that axis. In addition orin the alternative, the pivot axis may slide along slots (54) first,with anvil (60) then pivoting about the pivot axis after the pivot axishas slid a certain distance along the slots (54). It should beunderstood that such sliding/translating pivotal movement is encompassedwithin terms such as “pivot,” “pivots,” “pivotal,” “pivotable,”“pivoting,” and the like. Of course, some versions may provide pivotalmovement of anvil (60) about an axis that remains fixed and does nottranslate within a slot or channel, etc.

As best seen in FIG. 5, lower jaw (50) of the present example defines achannel (52) that is configured to receive a staple cartridge (70).Staple cartridge (70) may be inserted into channel (52), end effector(40) may be actuated, and then staple cartridge (70) may be removed andreplaced with another staple cartridge (70). Lower jaw (50) thusreleasably retains staple cartridge (70) in alignment with anvil (60)for actuation of end effector (40). In some versions, lower jaw (50) isconstructed in accordance with at least some of the teachings of U.S.patent application Ser. No. 13/780,417, entitled “Installation Featuresfor Surgical Instrument End Effector Cartridge,” filed Feb. 28, 2013,the disclosure of which is incorporated by reference herein. Othersuitable forms that lower jaw (50) may take will be apparent to those ofordinary skill in the art in view of the teachings herein.

As best seen in FIGS. 4-6, staple cartridge (70) of the present examplecomprises a cartridge body (71) and a tray (76) secured to the undersideof cartridge body (71). The upper side of cartridge body (71) presents adeck (73), against which tissue may be compressed when anvil (60) is ina closed position. Cartridge body (71) further defines a longitudinallyextending channel (72) and a plurality of staple pockets (74). A staple(77) is positioned in each staple pocket (74). A staple driver (75) isalso positioned in each staple pocket (74), underneath a correspondingstaple (77), and above tray (76). As will be described in greater detailbelow, staple drivers (75) are operable to translate upwardly in staplepockets (74) to thereby drive staples (77) upwardly through staplepockets (74) and into engagement with anvil (60). Staple drivers (75)are driven upwardly by a wedge sled (78), which is captured betweencartridge body (71) and tray (76), and which translates longitudinallythrough cartridge body (71). Wedge sled (78) includes a pair ofobliquely angled cam surfaces (79), which are configured to engagestaple drivers (75) and thereby drive staple drivers (75) upwardly aswedge sled (78) translates longitudinally through cartridge (70). Forinstance, when wedge sled (78) is in a proximal position as shown inFIG. 7A, staple drivers (75) are in downward positions and staples (74)are located in staple pockets (74). As wedge sled (78) is driven to thedistal position shown in FIG. 7B by a translating knife member (80),wedge sled (78) drives staple drivers (75) upwardly, thereby drivingstaples (74) out of staple pockets (74) and into staple forming pockets(64). Thus, staple drivers (75) translate along a vertical dimension aswedge sled (78) translates along a horizontal dimension.

It should be understood that the configuration of staple cartridge (70)may be varied in numerous ways. For instance, staple cartridge (70) ofthe present example includes two longitudinally extending rows of staplepockets (74) on one side of channel (72); and another set of twolongitudinally extending rows of staple pockets (74) on the other sideof channel (72). However, in some other versions, staple cartridge (70)includes three, one, or some other number of staple pockets (74) on eachside of channel (72). In some versions, staple cartridge (70) isconstructed and operable in accordance with at least some of theteachings of U. U.S. patent application Ser. No. 13/780,106, entitled“Integrated Tissue Positioning and Jaw Alignment Features for SurgicalStapler,” filed Feb. 28, 2013, the disclosure of which is incorporatedby reference herein. In addition or in the alternative, staple cartridge(70) may be constructed and operable in accordance with at least some ofthe teachings of U.S. patent application Ser. No. 13/780,417, entitled“Installation Features for Surgical Instrument End Effector Cartridge,”filed Feb. 28, 2013, the disclosure of which is incorporated byreference herein. Other suitable forms that staple cartridge (70) maytake will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

As best seen in FIG. 4, anvil (60) of the present example comprises alongitudinally extending channel (62) and a plurality of staple formingpockets (64). Channel (62) is configured to align with channel (72) ofstaple cartridge (70) when anvil (60) is in a closed position. Eachstaple forming pocket (64) is positioned to lie over a correspondingstaple pocket (74) of staple cartridge (70) when anvil (60) is in aclosed position. Staple forming pockets (64) are configured to deformthe legs of staples (77) when staples (77) are driven through tissue andinto anvil (60). In particular, staple forming pockets (64) areconfigured to bend the legs of staples (77) to secure the formed staples(77) in the tissue. Anvil (60) may be constructed in accordance with atleast some of the teachings of U.S. patent application Ser. No.13/780,106, entitled “Integrated Tissue Positioning and Jaw AlignmentFeatures for Surgical Stapler,” filed Feb. 28, 2013; at least some ofthe teachings of U.S. patent application Ser. No. 13/780,120, entitled“Jaw Closure Feature for End Effector of Surgical Instrument,” filedFeb. 28, 2013; and/or at least some of the teachings of U.S. patentapplication Ser. No. 13/780,379, entitled “Staple Forming Features forSurgical Stapling Instrument,” filed Feb. 28, 2013, the disclosure ofwhich is incorporated by reference herein. Other suitable forms thatanvil (60) may take will be apparent to those of ordinary skill in theart in view of the teachings herein.

In the present example, a knife member (80) is configured to translatethrough end effector (40). As best seen in FIGS. 5 and 7A-7B, knifemember (80) is secured to the distal end of a firing beam (82), whichextends through a portion of shaft assembly (30). As best seen in FIGS.4 and 6, knife member (80) is positioned in channels (62, 72) of anvil(60) and staple cartridge (70). Knife member (80) includes a distallypresented cutting edge (84) that is configured to cut tissue that iscompressed between anvil (60) and deck (73) of staple cartridge (70) asknife member (80) translates distally through end effector (40). Asnoted above and as shown in FIGS. 7A-7B, knife member (80) also driveswedge sled (78) distally as knife member (80) translates distallythrough end effector (40), thereby driving staples (74) through tissueand against anvil (60) into formation. Various features that may be usedto drive knife member (80) distally through end effector (40) will bedescribed in greater detail below.

In some versions, end effector (40) includes lockout features that areconfigured to prevent knife member (80) from advancing distally throughend effector (40) when a staple cartridge (70) is not inserted in lowerjaw (50). In addition or in the alternative, end effector (40) mayinclude lockout features that are configured to prevent knife member(80) from advancing distally through end effector (40) when a staplecartridge (70) that has already been actuated once (e.g., with allstaples (77) deployed therefrom) is inserted in lower jaw (50). By wayof example only, such lockout features may be configured in accordancewith at least some of the teachings of U.S. patent application Ser. No.13/780,082, entitled “Lockout Feature for Movable Cutting Member ofSurgical Instrument,” filed Feb. 28, 2013, the disclosure of which isincorporated by reference herein; and/or at least some of the teachingsbelow. Other suitable forms that lockout features may take will beapparent to those of ordinary skill in the art in view of the teachingsherein. Alternatively, end effector (40) may simply omit such lockoutfeatures.

C. Exemplary Actuation of Anvil

In the present example, anvil (60) is driven toward lower jaw (50) byadvancing closure ring (36) distally relative to end effector (40).Closure ring (36) cooperates with anvil (60) through a camming action todrive anvil (60) toward lower jaw (50) in response to distal translationof closure ring (36) relative to end effector (40). Similarly, closurering (36) may cooperate with anvil (60) to open anvil (60) away fromlower jaw (50) in response to proximal translation of closure ring (36)relative to end effector (40). By way of example only, closure ring (36)and anvil (60) may interact in accordance with at least some of theteachings of U.S. patent application Ser. No. 13/780,120, entitled “JawClosure Feature for End Effector of Surgical Instrument,” filed Feb. 28,2013, the disclosure of which is incorporated by reference herein;and/or in accordance with at least some of the teachings of U.S. PatentApp. No. [Attorney Docket Number END7430USNP.0614275], entitled “JawOpening Feature for Surgical Stapler,” filed on even date herewith, thedisclosure of which is incorporated by reference herein. Exemplaryfeatures that may be used to provide longitudinal translation of closurering (36) relative to end effector (40) will be described in greaterdetail below.

As noted above, handle assembly (20) includes a pistol grip (22) and aclosure trigger (24). As also noted above, anvil (60) is closed towardlower jaw (50) in response to distal advancement of closure ring (36).In the present example, closure trigger (24) is pivotable toward pistolgrip (22) to drive closure tube (32) and closure ring (36) distally.Various suitable components that may be used to convert pivotal movementof closure trigger (24) toward pistol grip (22) into distal translationof closure tube (32) and closure ring (36) relative to handle assembly(20) will be apparent to those of ordinary skill in the art in view ofthe teachings herein. When closure trigger (24) reaches a fully pivotedstate, such that anvil (60) is in a fully closed position relative tolower jaw (50), locking features in handle assembly (20) lock theposition of trigger (24) and closure tube (32), thereby locking anvil(60) in a fully closed position relative to lower jaw (50). Theselocking features are released by actuation of anvil release button (25).Anvil release button (25) is configured and positioned to be actuated bythe thumb of the operator hand that grasps pistol grip (22). In otherwords, the operator may grasp pistol grip (22) with one hand, actuateclosure trigger (24) with one or more fingers of the same hand, and thenactuate anvil release button (25) with the thumb of the same hand,without ever needing to release the grasp of pistol grip (22) with thesame hand. Other suitable features that may be used to actuate anvil(60) will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

D. Exemplary Actuation of Firing Beam

In the present example, instrument (10) provides motorized control offiring beam (82). FIGS. 9-12 show exemplary components that may be usedto provide motorized control of firing beam (82). In particular, FIG. 9shows an exemplary control circuit (100) that may be used to power anelectric motor (102) with electric power from a battery pack (28) (alsoshown in FIGS. 1-2). Electric motor (102) is operable to translatefiring beam (82) longitudinally as will be described in greater detailbelow. It should be understood that the entire control circuit (100),including motor (102) and battery pack (28), may be housed within handleassembly (20). FIG. 9 shows firing trigger (26) as an open switch,though it should be understood that this switch is closed when firingtrigger (26) is actuated. Circuit (100) of this example also includes asafety switch (106) that must be closed in order to complete circuit(100), though it should be understood that safety switch (106) is merelyoptional. Safety switch (106) may be closed by actuating a separatebutton, slider, or other feature on handle assembly (20). Safety switch(106) may also provide a mechanical lockout of firing trigger (26), suchthat firing trigger (26) is mechanically blocked from actuation untilsafety switch (106) is actuated.

Circuit (100) of the present example also includes a lockout switch(108), which is configured to be closed by default but is automaticallyopened in response to a lockout condition. By way of example only, alockout condition may include one or more of the following: the absenceof a cartridge (70) in lower jaw (50), the presence of a spent (e.g.,previously fired) cartridge (70) in lower jaw (50), an insufficientlyclosed anvil (60), a determination that instrument (10) has been firedtoo many times, and/or any other suitable conditions. Various sensors,algorithms, and other features that may be used to detect lockoutconditions will be apparent to those of ordinary skill in the art inview of the teachings herein. Similarly, other suitable kinds of lockoutconditions will be apparent to those of ordinary skill in the art inview of the teachings herein. It should be understood that circuit (100)is opened and thus motor (102) is inoperable when lockout switch (108)is opened. A lockout indicator (110) (e.g., an LED, etc.) is operable toprovide a visual indication of the status of lockout switch (108). Byway of example only, lockout switch (108), lockout indicator (110), andassociated components/functionality may be configured in accordance withat least some of the teachings of U.S. Pat. No. 7,644,848, entitled“Electronic Lockouts and Surgical Instrument Including Same,” issuedJan. 12, 2010, the disclosure of which is incorporated by referenceherein.

Once firing beam (82) reaches a distal-most position (e.g., at the endof a cutting stroke), an end-of-stroke switch (112) is automaticallyswitched to a closed position, reversing the polarity of the voltageapplied to motor (102). This reverses the direction of rotation of motor(102), it being understood that the operator will have released firingtrigger (26) at this stage of operation. In this operational state,current flows through a reverse direction indicator (114) (e.g., an LED,etc.) to provide a visual indication to the operator that motor (102)rotation has been reversed. In the present example, and as best seen inFIG. 12, a switch actuation arm (134) extends laterally from rack member(130), and is positioned to engage end-of-stroke switch (112) whenfiring beam (82) reaches a distal-most position (e.g., after tissue (90)has been severed and staples (74) have been driven into tissue (90)).Various other suitable ways in which end-of-stroke switch (112) may beautomatically switched to a closed position when firing beam (82)reaches a distal-most position will be apparent to those of ordinaryskill in the art in view of the teachings herein. Similarly, varioussuitable forms that reverse direction indicator (114) may take will beapparent to those of ordinary skill in the art in view of the teachingsherein.

Handle assembly (20) of the present example also includes a manualreturn switch (116), which is also shown in circuit (100). In thepresent example, return switch is activated by actuating reverse switch(27), which is shown on handle assembly (20) in FIG. 1. Manual returnswitch (116) may provide functionality similar to end-of-stroke switch(112), reversing the polarity of the voltage applied to motor (102) tothereby reverse the direction of rotation of motor (102). Again, thisreversal may be visually indicated through reverse direction indicator(114). In some versions, handle assembly (20) further includes amechanical return feature that enables the operator to manually reversefiring beam (82) and thereby retract firing beam (82) mechanically. Inthe present example, this manual return feature comprises a lever thatis covered by a removable panel (21) as shown in FIG. 1. Manual returnswitch (116) and the mechanical return feature are each configured toact as a “bailout” feature, enabling the operator to quickly beginretracting firing beam (82) proximally during a firing stroke. In otherwords, manual return switch (116) or the mechanical return feature maybe actuated when firing beam (82) has only been partially advanceddistally.

In some versions, one or more of switches (26, 106, 108, 112, 116) arein the form of microswitches. Other suitable forms will be apparent tothose of ordinary skill in the art in view of the teachings herein. Inaddition to or in lieu of the foregoing, at least part of circuit (100)may be configured in accordance with at least some of the teachings ofU.S. Pat. No. 8,210,411, entitled “Motor-Driven Surgical Instrument,”issued Jul. 3, 2012, the disclosure of which is incorporated byreference herein.

FIG. 10 shows motor (102) positioned within pistol grip (22) of handleassembly (20). Alternatively, motor (102) may be positioned elsewherewithin handle assembly (20). Motor (102) has a drive shaft (120) that iscoupled with a gear assembly (122). Thus, when motor (102) is activated,drive shaft (120) actuates gear assembly (122). As shown in FIG. 11,gear assembly (122) is in communication with a drive gear (124), whichmeshes with an idler pinion (126). Pinion (126) is disposed on a shaft(128) that is supported within handle assembly (20) and that is orientedparallel to drive shaft (120) of motor (102). Pinion (126) is furtherengaged with a rack member (130). In particular, pinion (126) mesheswith teeth (132) at the proximal end of rack member (130). Rack member(130) is slidably supported in handle assembly (20). It should beunderstood from the foregoing that, when motor (102) is activated, thecorresponding rotation of drive shaft (120) is communicated to pinion(126) via gear assembly (122), and the corresponding rotation of pinion(126) is converted to translation of rack member (130) by teeth (132).As shown in FIGS. 10-12, an elongate member (136) extends distally fromrack member (130). As shown in FIG. 12, a coupling member (138) joinsfiring beam (82) with elongate member (136). Rack member (130), elongatemember (136), coupling member (138), firing beam (82), and knife member(80) all translate together relative to handle assembly (20) in responseto activation of motor (102). In other words, activation of motor (102)ultimately causes firing beam (82) to translate longitudinally, thedirection of such translation depending on the direction of rotation ofdrive shaft (120).

It should be understood that a distal portion of elongate member (136),coupling member (138), and firing beam (82) extend through shaftassembly (130). A portion of firing beam (82) also extends througharticulation section (34). In some versions, rack member (130), elongatemember (136), and coupling member (138) are all substantially straightand rigid; while firing beam (82) has sufficient flexibility to bend atarticulation section (34) and translate longitudinally througharticulation section (34) when articulation section (34) is in a bent orarticulated state.

In addition to or in lieu of the foregoing, the features operable todrive firing beam (82) may be configured in accordance with at leastsome of the teachings of U.S. Pat. No. 8,453,914, the disclosure ofwhich is incorporated by reference herein. Other suitable components,features, and configurations for providing motorization of firing beam(82) will be apparent to those of ordinary skill in the art in view ofthe teachings herein. It should also be understood that some otherversions may provide manual driving of firing beam (82), such that amotor may be omitted. By way of example only, firing beam (82) may beactuated in accordance with at least some of the teachings of any otherreference cited herein.

FIG. 8 shows end effector (40) having been actuated through a singlestroke through tissue (90). As shown, cutting edge (84) (obscured inFIG. 8) has cut through tissue (90), while staple drivers (75) havedriven two alternating rows of staples (77) through the tissue (90) oneach side of the cut line produced by cutting edge (84). Staples (77)are all oriented substantially parallel to the cut line in this example,though it should be understood that staples (77) may be positioned atany suitable orientations. In the present example, end effector (40) iswithdrawn from the trocar after the first stroke is complete, the spentstaple cartridge (70) is replaced with a new staple cartridge (70), andend effector (40) is then again inserted through the trocar to reach thestapling site for further cutting and stapling. This process may berepeated until the desired amount of cuts and staples (77) have beenprovided. Anvil (60) may need to be closed to facilitate insertion andwithdrawal through the trocar; and anvil (60) may need to be opened tofacilitate replacement of staple cartridge (70).

It should be understood that cutting edge (84) may cut tissuesubstantially contemporaneously with staples (77) being driven throughtissue during each actuation stroke. In the present example, cuttingedge (84) just slightly lags behind driving of staples (77), such that astaple (47) is driven through the tissue just before cutting edge (84)passes through the same region of tissue, though it should be understoodthat this order may be reversed or that cutting edge (84) may bedirectly synchronized with adjacent staples. While FIG. 8 shows endeffector (40) being actuated in two layers (92, 94) of tissue (90), itshould be understood that end effector (40) may be actuated through asingle layer of tissue (90) or more than two layers (92, 94) of tissue.It should also be understood that the formation and positioning ofstaples (77) adjacent to the cut line produced by cutting edge (84) maysubstantially seal the tissue at the cut line, thereby reducing orpreventing bleeding and/or leaking of other bodily fluids at the cutline. Furthermore, while FIG. 8 shows end effector (40) being actuatedin two substantially flat, apposed planar layers (92, 94) of tissue, itshould be understood that end effector (40) may also be actuated acrossa tubular structure such as a blood vessel, a section of thegastrointestinal tract, etc. FIG. 8 should therefore not be viewed asdemonstrating any limitation on the contemplated uses for end effector(40). Various suitable settings and procedures in which instrument (10)may be used will be apparent to those of ordinary skill in the art inview of the teachings herein.

It should also be understood that any other components or features ofinstrument (10) may be configured and operable in accordance with any ofthe various references cited herein. Additional exemplary modificationsthat may be provided for instrument (10) will be described in greaterdetail below. Various suitable ways in which the below teachings may beincorporated into instrument (10) will be apparent to those of ordinaryskill in the art. Similarly, various suitable ways in which the belowteachings may be combined with various teachings of the references citedherein will be apparent to those of ordinary skill in the art. It shouldalso be understood that the below teachings are not limited toinstrument (10) or devices taught in the references cited herein. Thebelow teachings may be readily applied to various other kinds ofinstruments, including instruments that would not be classified assurgical staplers. Various other suitable devices and settings in whichthe below teachings may be applied will be apparent to those of ordinaryskill in the art in view of the teachings herein.

II. Exemplary End Effector Lockout Features

In some instances, it may be desirable to provide a lockout feature forend effector (40) to prevent inadvertent firing (i.e. distaladvancement) of firing beam (82) and cutting edge (84) so that tissuepositioned between anvil (60) and lower jaw (50) is not severed withoutbeing stapled. For example, it may be desirable to prevent firing beam(82) and cutting edge (84) from firing if a staple cartridge (70) hasnot been loaded within end effector (40) or after staples (77) have beendriven from staple cartridge (70). Accordingly, lockout features may beprovided within end effector (40) to prevent inadvertent firing offiring beam (82) and cutting edge (84). The examples below includeseveral merely illustrative versions of lockout features that may bereadily introduced to an end effector (40).

FIG. 13 shows an exemplary end effector (240) that may be readilyincorporated into instrument (10). End effector (240) comprises a lowerjaw (250), a pivotable anvil (260), and a closure ring (236), which aresimilar to lower jaw (50), anvil (60), and closure ring (36) of endeffector (40). A staple cartridge (270) may be removably installed intoa channel of lower jaw (250). Staple cartridge (270) of the presentexample is similar to staple cartridge (70) of end effector (40). Staplecartridge (270) comprises a cartridge body (271) that is coupled with alower cartridge tray (276). A wedge sled (278) and a plurality of stapledrivers (275) are captured between cartridge body (271) and tray (276),with wedge sled (278) being located proximal to staple drivers (275).Wedge sled (278) is slidably disposed within a channel (269) ofcartridge body (271). Although staples, similar to staples (47), havebeen omitted from FIG. 13 for clarity, it should be understood thatstaples (277) would be positioned directly above staple drivers (275).Wedge sled (278) and staple drivers (275) are similar to wedge sled (78)and staple drivers (75) of end effector (40) such that wedge sled (278)is configured to urge staple drivers (275) upwardly as wedge sled (278)is driven distally through channel (269) of staple cartridge (270) todrive staples (not shown in FIG. 13) vertically and into tissuepositioned between anvil (260) and lower jaw (250). Wedge sled (278) ofthe present example is driven distally by a translating knife member(280), which is positioned proximally of wedge sled (278). A firing beam(282) is coupled to knife member (280) (e.g., by welding). Firing beam(282) is similar to firing beam (82) and is configured to drive knifemember (280) distally and/or proximally. A resilient member (210) isproximal of knife member (280) and is configured to removably engageknife member (280). Knife member (280) and resilient member (210) arepositioned within a frame member (238). Frame member (238) is positionedwithin closure ring (236) and coupled to a proximal end of lower jaw(250) such that frame member (238) couples with articulation section(234) of shaft assembly (230).

Articulation section (234) and shaft assembly (230) are similar toarticulation section (34) and shaft assembly (30). By way of exampleonly, articulation section (234) and/or shaft assembly (230) may beconstructed in accordance with at least some of the teachings of U.S.patent application Ser. No. 13/780,067, entitled “Surgical InstrumentEnd Effector Articulation Drive with Pinion and Opposing Racks,” filedFeb. 28, 2013, the disclosure of which is incorporated by referenceherein; and/or U.S. patent application Ser. No. 13/780,402, entitled“Surgical Instrument with Multi-Diameter Shaft,” filed Feb. 28, 2013,the disclosure of which is incorporated by reference herein.Alternatively, articulation section (234) and/or shaft assembly (230)may have any other suitable configurations.

FIGS. 14-15 show knife member (280) in more detail. Knife member (280)comprises a cutting edge (284), an upper extension (290), and a lowerextension (285). Cutting edge (284) is positioned on an upper distalportion of knife member (280) such that cutting edge (284) severs tissueas knife member (280) translates distally through lower jaw (250). Upperextension (290) extends proximally from cutting edge (284). Upperextension (290) comprises walls (291, 292, 293, 294, 295, 296) on abottom surface of upper extension (290). Wall (291) extends proximallyto wall (292). Wall (292) ramps upwardly to wall (293). Wall (293)extends proximally to wall (294), which extends downwardly to wall(295). Walls (292, 293, 294) together form a notch. Wall (295) extendsproximally to wall (296), which ramps upwardly. Walls (294, 295, 296)form tab (298) that extends downwardly from upper extension (290). Tab(298) is configured to engage frame member (238) such that frame member(238) may prevent tab (298) and knife member (280) from advancingdistally without a loaded staple cartridge (270), as will be describedin greater detail below.

Lower extension (285) extends proximally from underneath cutting edge(284). A distal tip (297) and a distal wall (281) are positioned on adistal portion of lower extension (285). Distal tip (297) extendsdistally and downwardly from lower extension (285) such that distal tip(297) is configured to engage a top surface of wedge sled (278), as willbe described in greater detail below. Distal wall (281) is verticallypositioned on the distal portion of lower extension (285) beneath distaltip (297) such that distal wall (281) is configured to engage a proximalsurface of wedge sled (278), as will also be described in greater detailbelow. Accordingly, distal tip (297) and distal wall (281) releasablyengage wedge sled (278) when knife member (280) is translated distallywithin lower jaw (250) to thereby drive wedge sled (278) distally withinlower jaw (250). A rounded tab (286) extends upwardly from a proximalportion of lower extension (285). Tab (286) is configured to engageresilient member (280) such that resilient member (280) may bias tab(286) and knife member (280) downwardly such that tab (286) of knifemember (280) engages frame member (238) to prevent tab (286) and knifemember (280) from advancing distally without a loaded staple cartridge(270).

A protrusion (288) extends downwardly from lower extension (285) and isconfigured to translate within a slot (256) of lower jaw (250).Protrusion (288) is not as wide as lower extension (285) such that ashelf (283) is formed between protrusion (288) and lower extension (285)on a bottom surface of lower extension (285). Accordingly, shelf (283)retains knife member (280) in a vertical position within slot (256) oflower jaw (250), as best seen in FIG. 17. Shelf (283) creates aretention method without the need for added or extended portions beyondthe overall thickness of knife member (280). Protrusion (288) comprisesa ramped wall (211) sloping toward wall (212). Wall (212) extendsproximally to wall (218), which ramps downwardly to wall (214). Wall(214) extends proximally to wall (215) that ramps upwardly to lowerextension (285). Walls (218, 214, 215) form tab (289) that extendsdownwardly from protrusion (288).

Knife member (280) is configured to translate proximally and/or distallywithin lower jaw (250), based on the actuation of firing trigger (26) todrive motor (102) and firing beam (282). As shown in FIG. 16, lower jaw(250) comprises a slot (256) with a proximal portion (255) and a distalportion (253). Proximal portion (255) is wider than distal portion(253). Proximal portion (255) transitions to distal portion (253) viacamming surface (257). FIG. 17 shows knife member (280) positionedwithin slot (256) of lower jaw (250) when knife member (280) is at aproximal, unfired position. Slot (256) receives protrusion (288) ofknife member (280) such that protrusion (288) translates within slot(256) of lower jaw (250). Lower extension (285) is positioned above slot(256). Distal portion (253) of slot (256) has a lateral width sized tocorrespond to the lateral width of protrusion (288) such that shelf(283) extends laterally past distal portion (253) of slot (256) tomaintain the vertical alignment or position of knife member (280) whenknife member (280) is positioned within distal portion (253) of slot(256). Proximal portion (255) of slot (256) has a lateral width sized tocorrespond to the lateral width of lower extension (285) of knife member(280) such that protrusion (288) and lower extension (285) may fallwithin proximal portion (255) of slot (256) if knife member (280) isadvanced without a loaded staple cartridge (270).

Slot (256) extends continuously within lower jaw (250) to allow for thevisualization of the position of knife member (280) within lower jaw(250) as knife member (280) translates proximally and/or distally.Closure ring (236) is coupled to lower jaw (250) to further allow forvisualization of knife member (280). In the present example, closurering (236) comprises an opening (235), as shown in FIG. 22. Closure ring(236) is slidably coupled with lower jaw (250) such that opening (235)is adjacent to proximal portion (255) of slot (256) when closure ring(236) is advanced to a distal position to close anvil (260) againstlower jaw (250). Opening (235) is sized to correspond to tab (289) ofknife member (280) such that closure ring (236) allows for visualizationof tab (289) if protrusion (288) and lower extension (285) fall withinproximal portion (255) of slot (256).

The proximal end of lower jaw (250) is coupled with frame member (238),shown in FIGS. 18-19. Frame member (238) comprises a channel (233), apivot (239), and gear (231). A first engagement feature (222) and asecond engagement feature (224) are positioned within channel (233), asshown in FIG. 19. Engagement features (222, 224) are configured toengage upper extension (290) of knife member (280). First engagementfeature (222) comprises a wall (225) extending upwardly within channel(233). Wall (225) transitions to wall (223), which extends distally towall (221). Wall (221) slopes downwardly in the distal direction. Secondengagement feature (224) is proximal to first engagement feature (222).The top surface of second engagement feature (224) comprises a wall(227) extending distally to wall (226), which slopes downwardly in thedistal direction. The bottom surface of second engagement feature (224)comprises a wall (228) sloping downwardly in the proximal direction towall (229). Wall (229) extends proximally to wall (237), which extendsupwardly from wall (229). The bottom surface of second engagementfeature (224) is configured to engage resilient member (210), as shownin FIG. 23A. Gear (231) has teeth and is proximal to engagement feature(224). Pivot (239) extends upwardly from gear (231). Pivot (239) andgear (231) are configured to rotatably couple with articulation section(234) of shaft assembly (220) to allow end effector (240) to pivot to adesired angle (a) relative to shaft assembly (220). By way of exampleonly, gear (231) and/or other features of articulation section (234) maybe constructed in accordance with at least some of the teachings of U.S.patent application Ser. No. 13/780,067, entitled “Surgical InstrumentEnd Effector Articulation Drive with Pinion and Opposing Racks,” filedFeb. 28, 2013, the disclosure of which is incorporated by referenceherein; and/or U.S. application Ser. No. 13/780,162, entitled “SurgicalInstrument with Articulation Lock Having a Detenting Binary Spring,”filed Feb. 28, 2013, the disclosure of which is incorporated byreference herein.

FIGS. 20-21 show resilient member (210) in greater detail. Resilientmember (210) comprises a distal portion (213) and a proximal portion(285). Distal portion (213) comprises an opening (216) that isconfigured to receive tab (286) of lower extension (285) of knife member(280). Distal portion (213) transitions to proximal portion (217) viaramped portion (219) that slopes downwardly in the proximal direction.Ramped portion (219) is compliant and is configured to resiliently biasdistal portion (282) downwardly. A wall (209) extends upwardly from theproximal end of proximal portion (217). Wall (209) engages wall (237) offrame member (238) such that frame member (238) is configured to axiallyretain resilient member (210).

A. Exemplary Lockout Sequence

FIGS. 23A-23B show an attempt at firing knife member (280) without aproperly loaded staple cartridge (270). For instance, instrument (10)may be inserted to a surgical site in a nonarticulated state, with anvil(260) and lower jaw (250) closed. Once articulation section (234) andend effector (240) are inserted to the desired site within the patient,anvil (260) may be pivoted away from lower jaw (250) to the open endeffector (240) such that anvil (260) and lower jaw (250) may bepositioned about tissue. Articulation section (234) may be remotelyarticulated by articulation control knob (35), such that end effector(240) may be deflected to a desired angle (a). Closure trigger (24) maythen be actuated toward pistol grip (22) to cause the closing of anvil(260) toward lower jaw (250). Such closing of anvil (260) is providedthrough a closure tube (32) and closure ring (236), which bothlongitudinally translate relative to handle portion (20) and lower jaw(250) in response to pivoting of closure trigger (24) relative to pistolgrip (22). Articulation section (234) is operable to communicatelongitudinal movement from closure tube (32) to closure ring (236).

FIG. 23A shows end effector (240) in an initial position just afteranvil (260) and lower jaw (250) are closed, but without staple cartridge(270) in lower jaw (250). In the initial position, upper extension (290)of knife member (280) is positioned above engagement features (222, 224)of frame member (238). Wall (291) of upper extension (290) is resting onwall (223) of first engagement feature (222), while tab (298) of upperextension (290) is resting on wall (227) of second engagement feature(224). Resilient member (210) is positioned between lower jaw (250) andframe member (238). Wall (287) of resilient member (210) is engaged withwall (237) of frame member (238) such that wall (237) is configured toaxially retain resilient member (210). Opening (216) of resilient member(210) is positioned above lower extension (285) of knife member (280)such that tab (286) of lower extension (285) is positioned withinopening (216) of resilient member (210). Protrusion (288) of lowerextension (285) is positioned within proximal portion (255) of slot(256) of lower jaw (250). Protrusion (288) is vertically aligned withinslot (256) such that shelf (283) is positioned above slot (256).Accordingly, knife member (280) is ready to be fired in from the initialposition.

However, in the present example, a staple cartridge (270) was notproperly loaded in end effector (240). Accordingly, distal tip (297) anddistal wall (281) are not engaged with a sled (278). When firing trigger(26) is actuated to drive firing beam (282) and knife member (280)distally without a properly loaded staple cartridge (270), knife member(280) falls downwardly within end effector (240) to engage engagementfeatures (222, 224) of frame member (238) to prevent knife member (280)from travelling further distally within lower jaw (250), as shown inFIG. 23B. As knife member (280) is pushed distally without a properlyloaded staple cartridge (270), tab (286) of lower extension (285) ofknife member (280) translates distally from opening (216) of resilientmember (210). Tab (286) then engages distal portion (213) of resilientmember (210). Because distal portion (213) of resilient member (210) isbiased downwardly, resilient member (210) pushes tab (286) of knifemember (280) downward. This causes tab (298) of upper extension (290) ofknife member (280) to fall downwardly between engagement features (222,224). Accordingly, wall (294) of tab (298) engages wall (225) of firstengagement feature (222) to prevent knife member (280) from travellingany further distally to lock knife member (280) within end effector(240). It should be understood that the foregoing lockout may also occurwhen an operator intends to advance firing beam (282) from a proximalposition to a distal position when a spent staple cartridge (270) isloaded in end effector. The lockout features thus prevent advancement offiring beam (282) when no staple cartridge (270) is loaded in endeffector (240); and when a cartridge (270) that is in end effector (240)has already been fired and firing beam (282) has been retracted back toa proximal position.

As knife member (280) falls downwardly to the locked position shown inFIG. 23B, lower extension (285) and protrusion (288) of knife member(280) fall within proximal portion (255) of slot (256) of lower jaw(250). Accordingly, tab (289) of protrusion (288) extends throughproximal portion (255) of slot (256) and through opening (235) ofclosure ring (236). This provides a visual indication that knife member(280) is in the lockout position, as shown in FIGS. 24A-24B. In FIG.24A, knife member (280) is in the initial position such that tab (289)is positioned within slot (256) above opening (235) of closure ring(236). When knife member (280) falls downwardly to the lockout position,as shown in FIG. 24B, tab (289) extends through opening (235) of closurering (236) to provide a visual indication of lockout. By providinglockout features and visual indications within the space of closure ring(236), the overall length of articulation section (234) may beminimized.

Knife member (280) may be returned to the initial position of FIG. 23Aafter knife member (280) is in the lockout position of FIG. 23B. Forinstance, motor (102) may be activated to pull firing beam (282) andknife member (280) proximally to return knife member (280) to theinitial position of FIG. 23A. As knife member (280) translatesproximally, ramped walls (292, 296) of upper extension (290) of knifemember (280) slide proximally against ramped walls (221, 226) ofengagement features (222, 224). As upper extension (290) translatesproximally against engagement features (222, 224), walls (221, 226) ofengagement features (222, 224) push upper extension (290) and knifemember (280) upwardly through a camming action. Tab (286) of knifemember (280) also travels upwardly to again be positioned within opening(216) of resilient member (210). This returns knife member (280) to theinitial position, as shown in FIG. 23A.

B. Exemplary Firing Sequence

FIGS. 25A-25F show knife member (280) being fired with a properly loadedstaple cartridge (270). For instance, instrument (10) may be inserted toa surgical site in a nonarticulated state, with anvil (260) and lowerjaw (250) closed. Once articulation section (234) and end effector (240)are inserted to the desired site within the patient, anvil (260) may bepivoted away from lower jaw (250) to the open end effector (240) suchthat anvil (260) and lower jaw (250) may be positioned about tissue.Articulation section (234) may be remotely articulated by articulationcontrol knob (35), such that end effector (240) may be deflected to adesired angle (a). Closure trigger (24) may then be actuated towardpistol grip (22) to cause the closing of anvil (260) toward lower jaw(250). Such closing of anvil is provided through closure tube (32) andclosure ring (236), which both longitudinally translate relative tohandle portion (20) and lower jaw (250) in response to pivoting ofclosure trigger (24) relative to pistol grip (22). Articulation section(234) is operable to communicate longitudinal movement from closure tube(32) to closure ring (236).

FIG. 25A shows end effector (240) in an initial position just afteranvil (260) and lower jaw (250) are closed with a properly loaded staplecartridge (270). In the initial position, upper extension (290) of knifemember (280) is positioned above engagement features (222, 224) of framemember (238). Wall (291) of upper extension (290) is resting on wall(223) of first engagement feature (222), while tab (298) of upperextension (290) is resting on wall (227) of second engagement feature(224). Resilient member (210) is positioned between lower jaw (250) andframe member (238). Wall (209) of resilient member (210) is engaged withwall (237) of frame member (238) such that wall (237) is configured toaxially retain resilient member (210). Opening (216) of resilient memberis positioned above lower extension (285) of knife member (280) suchthat tab (286) of lower extension (285) is positioned within opening(216) of resilient member (210). Protrusion (288) of lower extension(285) is positioned within proximal portion (255) of slot (256) of lowerjaw (250). Protrusion (288) is vertically aligned within slot (256) suchthat shelf (283) is positioned above slot (256). Distal tip (297) ofknife member (280) is positioned above sled (278). Accordingly, knifemember (280) is ready to be fired in from the initial position shown inFIG. 25A.

Firing trigger (26) may be actuated to drive firing beam (282) and knifemember (280). As knife member (280) is driven distally, distal tip (297)of knife member (280) engages a top surface (279) of sled (278) anddistal wall (281) of knife member (280) engages a proximal end (276) ofsled (278), as shown in FIG. 25B. This maintains the vertical positionof knife member (280) when knife member is positioned within proximalportion (255) of slot (256) of lower jaw (250). As knife member (280)travels further distally, tab (286) of knife member (280) travelsdistally from opening (216) of resilient member (210) such that tab(286) engages distal portion (213) of resilient member (210). Tab (286)thereby pushes distal portion (213) of resilient member (210) upwardly,as shown in FIG. 25C. Because sled (278) maintains the vertical positionof knife member (280), tab (298) of knife member (280) translatesdistally above engagement features (222, 224) of frame member (238) suchthat tab (298) does not fall between engagement features (222, 224) toprevent the distal movement of knife member (280), as shown in FIG. 25D.Knife member (280) thus overrides the lockout position at this stage.Distal portion (213) of resilient member (210) then biases downwardly toa nominal position, proximal of tab (286) of knife member (280), as tab(286) translates distally from resilient member (210), as shown in FIG.25E. Protrusion (288) of knife member (280) then enters distal portion(253) of slot (256) of lower jaw (250), as shown in FIG. 25F. Shelf(283) of knife member (280) is then positioned above slot (256) and tab(298) of upper extension (290) is above first engagement feature (222).Knife member (280) is then further translated distally to cut and stapletissue positioned between anvil (260) and lower jaw (250).

After knife member (280) is fired distally, knife member (280) may beretracted proximally within lower jaw (250). For example, knife member(280) may be retracted by firing beam (282) by automatic reversal ofmotor (102) upon detected completion of a firing stroke, in response toa second actuation of firing trigger (26), and/or otherwise. When knifemember (280) is retracted, knife member (280) disengages from sled(278). Without sled (280), knife member (280) may fall downwardly to thelockout position of FIG. 23B as knife member (280) is retracted afterbeing fired. Knife member (280) may be returned to the initial positionof FIG. 23A after knife member (280) is in the lockout position of FIG.23B. As knife member (280) is driven proximally by motor (102), rampedwalls (292, 296) of upper extension (290) of knife member (280) slideproximally against ramped walls (221, 226) of engagement features (222,224). As upper extension (290) translates proximally against engagementfeatures (222, 224), walls (221, 226) of engagement features (222, 224)push upper extension (290) and knife member (280) upwardly through acamming action. Tab (286) of knife member (280) also travels upwardly toagain be positioned within opening (216) of resilient member (210). Thisreturns knife member (280) to the initial position, as shown in FIG.23A.

Once tissue positioned between anvil (260) and lower jaw (250) is cutand stapled, end effector (240) may be pivoted back to thenonarticulated position by articulation control knob (35) and removedfrom the surgical site, with anvil (260) and lower jaw (250) closed.Alternatively, anvil (260) and lower jaw (250) may be opened prior topivoting end effector (240) to release any tissue between anvil (260)and lower jaw (250). Anvil (260) and lower jaw (250) may then bere-closed prior to removing end effector (240) from the surgical site.End effector (240) may then be opened to replace staple cartridge (270)with a new staple cartridge. To open end effector (240), closure trigger(24) may be released away from pistol grip (22). Staple cartridge (270)may be replaced with a new staple cartridge, and end effector (240) maybe again inserted to the surgical site for further cutting and stapling.

In some variations, frame member (238) and knife member (280) arereconfigured such that wall (225) and wall (294) are located at or nearthe underside of the distal end of knife member (280). For instance,frame member (238) may include a feature that is substantially identicalto first engagement feature (222) that is located near protrusion (288)of lower extension (285); and protrusion (288) of lower extension (285)may include a feature that is substantially identical to tab (298).Other suitable locations in which functional equivalents of walls (225,294) may engage to provide a lockout against distal translation of knifemember (280) will be apparent to those of ordinary skill in the art inview of the teachings herein.

III. Exemplary Alternative Spent Cartridge Lockout Features

In some instances, it may be desirable to provide features that preventknife member (280) from being fired through the same staple cartridge(270) more than once, such that knife member (280) may not be firedthrough a “spent” staple cartridge (270). For example, such a featuremay prevent knife member (280) from engaging the lockout features (222,224) of frame member (238) discussed above upon being fired through astaple cartridge (270) a first time. However, upon subsequent attemptsto fire knife member (280) such a feature would provide engagementbetween knife member (280) and lockout features (222, 224) of framemember (238) to thereby prevent firing of knife member (280) through thesame staple cartridge (270) a second time. The examples below includeseveral merely illustrative versions of spent staple cartridge (270)lockout features that may be readily introduced to an end effector suchas end effector (240).

A. Exemplary Cartridge with Resilient Tab

FIGS. 26-29D show an exemplary cartridge (300) having a spent cartridgelockout feature. It should be understood that cartridge (300) may bereadily used in end effector (240) or in other end effectors. Cartridge(300) of the present example is configured to operate substantiallysimilar to cartridges (70, 270) discussed above except for thedifferences discussed below. Cartridge (300) includes a cartridge body(301) having a longitudinal channel (304) through which wedge sled (278)and knife member (280) may be longitudinally translated. The spentcartridge lockout feature of the present example comprises a resilienttab (310). As best seen in FIG. 27, an interior surface of channel (304)of cartridge body (301) comprises a rectangular recess (302) withinwhich resilient tab (310) is pivotably disposed. Resilient tab (310) ispivotably secured within rectangular recess (302) via a living hinge.Resilient tab (310) is pivotable between an unexposed position, in whichresilient tab (310) is substantially completely disposed withinrectangular recess (302); and an exposed position, in which resilienttab (310) extends from rectangular recess (302) into channel (304) andthus in the pathway of the distally translating knife member (280).Resilient tab (310) of the present example is biased toward the exposedposition shown in FIGS. 26-27 and 29D. Resilient tab (310) is configuredto allow for firing of knife member (280) when in the unexposed positionand to prevent firing of knife member (280) when in the exposedposition.

As best seen in FIG. 28, wedge sled (278), is positioned within channel(304) of cartridge (300) and is operable to translate longitudinallythrough channel (304) of cartridge (300). In an initial position (FIGS.28 and 29A), wedge sled (278) proximally is positioned so as to maintainresilient tab (310) in the unexposed position. As knife member (280) isfired a first time, knife member (280) engages wedge sled (278) (FIG.29B) and drives wedge sled (278) distally as described above (FIG. 29C).As knife member (280) is being fired, knife member (280) and/or firingbeam (282) are configured to maintain resilient tab (310) in theunexposed position. Once knife member (280) is retracted into theinitial position, wedge sled (278), knife member (280), and/or firingbeam (282) are no longer in a position to maintain resilient tab (310)in the unexposed position such that resilient tab (310) resilientlydeflects into the exposed position (FIG. 29D). In the exposed position,resilient tab (310) will engage knife member (280) if the operatorattempts to advance knife member (280) distally a second time, therebypreventing firing of knife member (280) a second time through cartridge(300).

B. Exemplary Cartridge with Bypass Beam

FIGS. 30-32E show another exemplary cartridge (320) having a spentcartridge lockout feature. It should be understood that cartridge (320)may be readily used in end effector (240) or in other end effectors.Cartridge (320) of the present example is configured to operatesubstantially similar to cartridges (70, 270) discussed above except forthe differences discussed below. Cartridge (320) includes a cartridgebody (322) having a longitudinal channel (324) through which wedge sled(278) and knife member (280) may be longitudinally translated. The spentcartridge lockout feature of the present example comprises a breakawayor cutaway beam (330) extending between opposing interior surfaces ofchannel (324). Beam (330) is positioned within channel (324) such thatbeam (330) is in the path of knife member (280). Beam (330) of thepresent example comprises a square cross-sectional profile, but maycomprise any other appropriate shape. As will be discussed in moredetail below, as knife member (280) is fired distally through channel(324), knife member (280) is configured to break and/or cut beam (330).Also as will be discussed in more detail below, beam (330) is configuredto allow for firing of knife member (280) when beam (330) is present;and to prevent firing of knife member (280) when beam (330) is notpresent.

FIG. 32A shows end effector (240) in an initial position. In the initialposition, upper extension (290) of knife member (280) is positionedabove engagement features (222, 224) of frame member (238). Also in theinitial position, distal tip (297) of knife member (280) is in contactwith a top surface of beam (330) of cartridge (320). As knife member(280) is fired distally, distal tip (297) of knife member (280)continues to engage the top surface of beam (330) as distal wall (281)of knife member (280) engages a proximal end (276) of sled (278), asshown in FIG. 32B. Engagement between distal tip (297) and the topsurface of beam (330) maintains the vertical position of knife member(280). Because beam (330) maintains the vertical position of knifemember (280), tab (298) of knife member (280) translates distally aboveengagement features (222, 224) of frame member (238) such that tab (298)does not fall between engagement features (222, 224) to prevent thedistal movement of knife member (280). As knife member (280) is firedfurther distally, knife member (280) breaks and/or cuts beam (330) asknife member (280) drives wedge sled (278) distally as described above(FIG. 32C). After knife member (280) is fired distally, knife member(280) may be retracted proximally within lower jaw (250) (FIG. 32D). Ifan operator attempts to fire knife member (280) a second time, withoutbeam (330) to maintain the vertical position of knife member (280),resilient member (210) will resiliently drive knife member (280)downwardly to the lockout position as discussed above with reference toFIG. 23B and as shown in FIG. 32E.

C. Exemplary Cartridge with Bypass Ramp

FIGS. 33-36E show another exemplary cartridge (340) having a spentcartridge lockout feature. It should be understood that cartridge (340)may be readily used in end effector (240) or in other end effectors.Cartridge (340) of the present example is configured to operatesubstantially similar to cartridges (70, 270) discussed above except forthe differences discussed below. Cartridge (340) includes a cartridgebody (342) having a longitudinal channel (344) through which wedge sled(278) and knife member (280) may be longitudinally translated. The spentcartridge lockout feature of the present example comprises a breakawayor cutaway ramp (350) extending between opposing interior surfaces ofchannel (344) of cartridge body (342). Ramp (350) is positioned withinchannel (344) such that ramp (350) is in the path of knife member (280).As best shown in FIG. 34, ramp (350) of the present example is angledupwardly-distally. As will be discussed in more detail below, as knifemember (280) is fired distally through channel (344), knife member (280)is configured to break and/or cut ramp (350). Also as will be discussedin more detail below, ramp (350) is configured to allow for firing ofknife member (280) when ramp (350) is present; and to prevent firing ofknife member (280) when ramp (350) is not present.

FIG. 36A shows end effector (240) in an initial position. In the initialposition, upper extension (290) of knife member (280) is positionedabove engagement features (222, 224) of frame member (238). Also in theinitial position, distal tip (297) of knife member (280) is in contactwith a top surface of ramp (350) of cartridge (340). As knife member(280) is fired distally, distal tip (297) of knife member (280)continues to engage the top surface of beam (330) as distal wall (281)of knife member (280) engages a proximal end (276) of sled (278), asshown in FIG. 36B. Engagement between distal tip (297) and the topsurface of ramp (350) maintains the vertical position of knife member(280). Because ramp (350) maintains the vertical position of knifemember (280), tab (298) of knife member (280) translates distally aboveengagement features (222, 224) of frame member (238) such that tab (298)does not fall between engagement features (222, 224) to prevent thedistal movement of knife member (280). As knife member (280) is firedfurther distally, knife member (280) breaks and/or cuts ramp (350) asknife member (280) drives wedge sled (278) distally as described above(FIG. 36C). After knife member (280) is fired distally, knife member(280) may be retracted proximally within lower jaw (250) (FIG. 36D). Ifan operator attempts to fire knife member (280) a second time, withoutramp (350) to maintain the vertical position of knife member (280),resilient member (210) will resiliently drive knife member (280)downwardly to the lockout position as discussed above with reference toFIG. 23B and as shown in FIG. 36E.

D. Exemplary Cartridge with Bypass Tabs

FIGS. 37-41E show another exemplary cartridge (360) having a spentcartridge lockout feature. It should be understood that cartridge (360)may be readily used in end effector (240) or in other end effectors.Cartridge (360) of the present example is configured to operatesubstantially similar to cartridges (70, 270) discussed above except forthe differences discussed below. Cartridge (360) includes a cartridgebody (362) having a longitudinal channel (363) through which wedge sled(278) and knife member (280) may be longitudinally translated. The spentcartridge lockout feature of the present example comprises a pair oftabs (370, 372) extending from opposing interior surfaces of channel(363) of cartridge body (362). The interior surfaces of channel (364) ofcartridge body (362) comprise a pair rectangular recesses (364, 366)within which tabs (370, 372) are pivotably disposed. Tabs (370) arepivotably secured within rectangular recesses (364, 366) via livinghinges. Each tab (370, 372) is pivotable between an unexposed position,in which tabs (370, 372) are substantially completely disposed withinrectangular recesses (364, 366); and an exposed position, in which tabs(370, 372) are substantially completely disposed outside of rectangularrecesses (364, 366) and are positioned within channel (363), orientedsubstantially orthogonal to the respective interior surfaces of channel(363) of cartridge body (362). As will be discussed in more detailbelow, as knife member (280) is fired distally through channel (363),knife member (280) is configured to drive tabs (370, 372) from theexposed position toward the unexposed position. Tabs (370, 372) areconfigured to remain in the unexposed position once driven into theunexposed position. Also as will be discussed in more detail below, tabs(370, 372) are configured to allow for firing of knife member (280) whentabs (370, 372) are in the exposed position; and to prevent firing ofknife member (280) when tabs (370, 372) are in the unexposed position.

FIG. 41A shows end effector (240) in an initial position. In the initialposition, upper extension (290) of knife member (280) is positionedabove engagement features (222, 224) of frame member (238). Also in theinitial position, tabs (370, 372) are in the exposed position and distaltip (297) of knife member (280) is in contact with a top surface of oneor both tabs (370, 372) of cartridge (360). As knife member (280) isfired distally, distal tip (297) of knife member (280) continues toengage the top surface of one or both tabs (370, 372) as distal wall(281) of knife member (280) engages a proximal end (276) of sled (278),as shown in FIG. 41B. Engagement between distal tip (297) and of one orboth tabs (370, 372) maintains the vertical position of knife member(280). Because one or both tabs (370, 372) maintain the verticalposition of knife member (280), tab (298) of knife member (280)translates distally above engagement features (222, 224) of frame member(238) such that tab (298) does not fall between engagement features(222, 224) to prevent the distal movement of knife member (280). Asknife member (280) is fired further distally, knife member (280) drivestabs (370, 372) into the unexposed position as knife member (280) driveswedge sled (278) distally as described above (FIG. 41C). After knifemember (280) is fired distally, knife member (280) may be retractedproximally within lower jaw (250) (FIG. 41D). If an operator attempts tofire knife member (280) a second time, with tabs (370, 372) in theunexposed position, tabs (370, 372) no longer maintain the verticalposition of knife member (280), resilient member (210) will resilientlydrive knife member (280) downwardly to the lockout position as discussedabove with reference to FIG. 23B and as shown in FIG. 41E.

E. Exemplary Cartridges with Bypass Fins

FIGS. 42 and 43 show another exemplary cartridge (460) having a spentcartridge lockout feature. It should be understood that cartridge (460)may be readily used in end effector (240) or in other end effectors.Cartridge (460) of the present example is configured to operatesubstantially similar to cartridges (70, 270) discussed above except forthe differences discussed below. Cartridge (460) includes a cartridgebody (466) having a longitudinal channel (467) through which wedge sled(278) and knife member (280) may be longitudinally translated. The spentcartridge lockout feature of the present example comprises a pair offins (462, 464) extending upwardly and proximally from a cartridge body(466). A plurality of breakaway or cutaway pins (468) within a gap (463)defined between fins (462, 464). Gap (463) between fins (462, 464) isaligned with channel (467) of cartridge body (466) such that pins (468)are in the path of distally translating knife member (280). As will bediscussed in more detail below, as knife member (280) is fired distallythrough channel (467) and gap (463), knife member (280) is configured tobreak and/or cut pins (468). Also as will be discussed in more detailbelow, pins (468) are configured to allow for firing of knife member(280) when pins (468) are present and to prevent firing of knife member(280) when pins (468) are not present.

FIGS. 44A-45B show another exemplary cartridge (470) having a spentcartridge lockout feature. It should be understood that cartridge (470)may be readily used in end effector (240) or in other end effectors.Cartridge (470) of the present example is configured to operatesubstantially similar to cartridges (70, 270) discussed above except forthe differences discussed below. Cartridge (470) includes a cartridgebody (476) having a longitudinal channel (477) through which wedge sled(278) and knife member (280) may be longitudinally translated. The spentcartridge lockout feature of the present example comprises a pair ofmalleable fins (472, 474) extending upwardly and proximally from acartridge body (476). Initially, fins (472, 474) are in a closedposition as shown in FIGS. 44A and 45A. In the closed position, fins(472, 474) contact each other along a plane aligned with channel (477)of cartridge body (476), such that fins (472, 474) are in the path ofdistally translating knife (280). As will be discussed in more detailbelow, as knife member (280) is fired distally through channel (467),knife member (280) is configured to drive fins (472, 474) outwardly intoan open position as shown in FIGS. 44B and 45B. Fins (472, 474) areconfigured to remain in the open position upon being driven into theopen position by firing of knife member (280). As will be discussed inmore detail below, fins (468) are configured to allow for firing ofknife member (280) when fins (472, 474) are in the closed position; andto prevent firing of knife member (280) when fins (472, 474) in the openposition.

FIG. 46 shows end effector (240) in an initial position. In the initialposition, upper extension (290) of knife member (280) is positionedabove engagement features (222, 224) of frame member (238). Also in theinitial position, a distal protrusion (299) of knife member (280) is incontact with a top surface of pins (468) of cartridge (460) or fins(472, 474) of cartridge (470). (Although cartridge (470) is beingdiscussed in the present example, it should be appreciated thatcartridge (460) may alternatively be used.) As knife member (280) isfired distally, distal protrusion (299) of knife member (280) continuesto engage the top surface of pins (468) or fins (472, 474) so as tomaintain the vertical position of knife member (280). Because pins (468)or fins (472, 474) maintain the vertical position of knife member (280),tab (298) of knife member (280) translates distally above engagementfeatures (222, 224) of frame member (238) such that tab (298) does notfall between engagement features (222, 224) to prevent the distalmovement of knife member (280). As knife member (280) is fired furtherdistally, knife member (280) breaks and/or cuts pins (468) or drivesfins (472, 474) outwardly into the open position as knife member (280)drives wedge sled (278) distally as described above. After knife member(280) is fired distally, knife member (280) may be retracted proximallywithin lower jaw (250). If an operator attempts to fire knife member(280) a second time, without pins (468) or fins (472, 474) to maintainthe vertical position of knife member (280), resilient member (210) willresiliently drive knife member (280) downwardly to the lockout positionas discussed above with reference to FIG. 23B.

IV. Exemplary Permanent Lockout Bypass Features in Cartridge

In some instances, it may be desirable to provide other features in astaple cartridge (270) that enable the knife member (280) to bypasslockout features (222, 224) of frame member (238) discussed above tothereby allow continuous firing (i.e. distal advancement) of firing beam(282) and knife member (280) so that tissue positioned between anvil(260) and lower jaw (250) may be severed and stapled. For example, sucha feature may prevent knife member (280) from engaging the lockoutfeatures of frame member (238) discussed above upon being fired. Theexamples below include several merely illustrative versions of lockoutbypass features that may be readily incorporated into a staple cartridge(270) that is coupled with an end effector such as end effector (240).The examples discussed below provide a lockout bypass in lieu of havingwedge sled (278) provide a lockout bypass as discussed above. Theexamples discussed below are also permanent, permitting re-firing offiring beam (282) and knife member (280) through a spent staplecartridge (270).

A. Exemplary Cartridge Tray with Projection

FIGS. 47-49B show an exemplary cartridge tray (380) having a lockoutbypass feature. It should be understood that cartridge tray (380) may bereadily used in staple cartridge (270) or in other staple cartridges.Cartridge tray (380) of the present example is configured to operatesubstantially similar to cartridge trays (76, 276) discussed aboveexcept for the differences discussed below. Cartridge tray (380)includes a longitudinal slot (381) through which protrusion (288) ofknife member (280) may be longitudinally translated. Slot (381) issubstantially aligned with channel (269) of cartridge (270). The lockoutbypass feature of the present example comprises an inwardly extendingprojection (382). Projection (382) extends transversely inwardly withinthe proximal end of slot (381). Projection (382) is configured to engageshelf (283) of knife member (280) as knife member (280) is fired; yetprojection (382) provides enough clearance for protrusion (288) of knifemember (280) to traverse longitudinally through channel (269) ofcartridge (270). As will be discussed in more detail below, projection(382) is configured to allow for firing of knife member (280) bypreventing engagement of knife member (280) with the lockout features offrame member (238) as discussed above.

FIG. 49A shows components of end effector (240) in an initial position.In the initial position, upper extension (290) of knife member (280) ispositioned above engagement features (222, 224) of frame member (238).As knife member (280) is fired distally, shelf (283) of knife member(280) engages a top surface projection (382). Engagement between shelf(283) and projection (382) maintains the vertical position of knifemember (280). Because projection (382) maintains the vertical positionof knife member (280), tab (298) of knife member (280) translatesdistally above engagement features (222, 224) of frame member (238) suchthat resilient member (210) does not drive tab (298) downwardly betweenengagement features (222, 224) to prevent the distal movement of knifemember (280).

B. Exemplary Cartridge Body with Projections

FIGS. 50-52B show another exemplary staple cartridge (400) having alockout bypass feature. It should be understood that cartridge (400) maybe readily used in end effector (240) or in other end effectors.Cartridge (400) of the present example is configured to operatesubstantially similar to cartridges (70, 270) discussed above except forthe differences discussed below. Cartridge (400) includes a cartridgebody (402) having a longitudinal channel (408) through which wedge sled(278) and knife member (280) may be longitudinally translated. Thelockout bypass feature of the present example comprises a pair ofinwardly extending projections (404, 406) extending inwardly fromopposing interior surfaces of channel (408) of cartridge body (402).Projections (404, 406) are configured to engage distal tip (297) ofknife member (280) as knife member (280) is fired; yet projections (404,406) provide enough clearance for knife member (280) to translatelongitudinally through channel (408) of cartridge (400). As will bediscussed in more detail below, projections (404, 406) are configured toallow for firing of knife member (280) by preventing engagement of knifemember (280) with the lockout features of frame member (238) asdiscussed above.

FIG. 52A shows end effector (240) in an initial position. In the initialposition, upper extension (290) of knife member (280) is positionedabove engagement features (222, 224) of frame member (238). As knifemember (280) is fired distally to the position shown in FIG. 52B, distaltip (297) of knife member (280) engages a top surface of one or bothprojections (404, 406). Engagement between distal tip (297) and one orboth projections (404, 406) maintains the vertical position of knifemember (280). Because one or both projections (404, 406) maintain thevertical position of knife member (280), tab (298) of knife member (280)translates distally above engagement features (222, 224) of frame member(238) such that resilient member (210) does not drive tab (298)downwardly between engagement features (222, 224) to prevent the distalmovement of knife member (280).

C. Exemplary Cartridge with Proximal Ramp

FIGS. 53-56 show another exemplary staple cartridge (410) having alockout bypass feature. It should be understood that cartridge (410) maybe readily used in end effector (240) or in other end effectors.Cartridge (410) of the present example is configured to operatesubstantially similar to cartridges (70, 270) discussed above except forthe differences discussed below. The lockout bypass feature of thepresent example comprises a resilient ramp (412) extending proximallyfrom a proximal end of cartridge (410). Ramp (412) is configured toengage ramped wall (211) and/or tab (289) of knife member (280) as knifemember (280) is fired distally. Ramp (412) is configured to allow forfiring of knife member (280) by preventing engagement of knife member(280) with the lockout features of frame member (238) as discussed aboveupon being fired. In particular, as shown in FIG. 56, with cartridge(410) positioned within lower jaw (250), ramp (410) covers opening (235)of closure ring (236) and provides a surface operable to engage rampedwall (211) and/or tab (289) of knife member (280) as knife member (280)is fired. As knife member (280) is fired distally, ramped wall (211)and/or tab (289) of knife member (280) engages a top surface of ramp(412). Engagement between ramped wall (211) and/or tab (289) and ramp(412) maintains the vertical position of knife member (280). Becauseramp (412) maintains the vertical position of knife member (280), tab(298) of knife member (280) translates distally above engagementfeatures (222, 224) of frame member (238) such that resilient member(210) does not drive tab (298) downwardly between engagement features(222, 224) to prevent the distal movement of knife member (280).

It should also be understood that a variation of cartridge (410) may beused in other kinds of surgical staplers. By way of example only, avariation of cartridge (410) may be used in any of the various surgicalstaplers disclosed in U.S. Pat. No. 7,380,695, entitled “SurgicalStapling Instrument Having a Single Lockout Mechanism for Prevention ofFiring,” issued Jun. 3, 2008, the disclosure of which is incorporated byreference herein. For instance, ramp (412) may engage the “middle pin46” of the “firing bar 14” of that stapler, such that the “middle pin46” rides along the top surface of ramp (412). This may provide a bypassof a lockout assembly as taught in that reference, such that ramp (412)enables the “firing bar 14” to advance distally without being lockedout. Various other suitable ways in which ramp (412) and other lockoutbypass features described herein may be incorporated into other staplinginstruments will be apparent to those of ordinary skill in the art inview of the teachings herein.

D. Exemplary Snap-Fit Cover

FIGS. 57-59B show another exemplary lockout bypass feature. The lockoutbypass feature of the present example comprises a snap-fit cover (420).Cover (420) is configured to engage tab (289) of knife member (280) asknife member (280) is fired. Cover (420) is configured to allow forfiring of knife member (280) by preventing engagement of knife member(280) with the lockout features of frame member (238) as discussed aboveupon firing of knife member (280). In particular, as best seen in FIGS.59A and 59B, cover (420) is configured to be positioned within opening(235) of closure ring (236) such that a projection (422) of cover (420)extends inwardly within closure ring (236). As knife member (280) isfired distally, tab (289) of knife member (280) engages a top surface ofprojection (422) of cover (420). Engagement between tab (289) andprojection (422) maintains the vertical position of knife member (280).Because projection (422) maintains the vertical position of knife member(280), tab (289) of knife member (280) translates distally aboveengagement features (222, 224) of frame member (238) such that resilientmember (210) does not drive tab (298) downwardly between engagementfeatures (222, 224) to prevent the distal movement of knife member(280). It should be understood that cover (420) may be readily used inend effector (240) or in other end effectors.

E. Exemplary Snap-Fit Ramp

FIGS. 60 and 61 show another exemplary lockout bypass feature. Thelockout bypass feature of the present example comprises a snap-fit ramp(440). Ramp (440) is configured to engage ramped wall (211) and/or tab(289) of knife member (280) as knife member (280) is fired. Ramp (440)is configured to allow for firing of knife member (280) by preventingengagement of knife member (280) with the lockout features of framemember (238) as discussed above upon being fired. In particular, as bestseen in FIG. 61, ramp (440) is configured to be positioned withinopening (235) of closure ring (236) such that ramp (440) extendsinwardly within closure ring (236). A step (442) of ramp (440) engages adistal edge of opening (235) to maintain the position of ramp (440)during firing of knife member (280). As knife member (280) is fireddistally, ramped wall (211) and/or tab (289) of knife member (280)engages a top surface of ramp (440). Engagement between ramped wall(211) and/or tab (289) and ramp (440) maintains the vertical position ofknife member (280). Because ramp (440) maintains the vertical positionof knife member (280), tab (298) of knife member (280) translatesdistally above engagement features (222, 224) of frame member (238) suchthat resilient member (210) does not drive tab (298) downwardly betweenengagement features (222, 224) to prevent the distal movement of knifemember (280). It should be understood that ramp (440) may be readilyused in end effector (240) or in other end effectors.

F. Exemplary Cartridge Body with Proximal Supports

FIGS. 62-64B show another exemplary staple cartridge (450) having alockout bypass feature. It should be understood that cartridge (450) maybe readily used in end effector (240) or in other end effectors.Cartridge (450) of the present example is configured to operatesubstantially similar to cartridges (70, 270) discussed above except forthe differences discussed below. The lockout bypass feature of thepresent example comprises a pair of proximally extending resilientsupports (452, 454). Supports (452, 454) are configured to engageresilient member (210) to prevent resilient member (210) from bearingupon knife member (280). By preventing resilient member (210) frombearing upon knife member (280), supports (452, 454) are configured toallow for firing of knife member (280) by preventing engagement of knifemember (280) with the lockout features of frame member (238) asdiscussed above. In particular, as shown in FIGS. 64A and 64B, withcartridge (450) positioned within lower jaw (250), supports (452, 454)engage resilient member (210) and drive resilient member (210) upwardly,thereby holding resilient member (210) in the upward position. FIG. 64Ashows end effector (240) in an initial position. In the initialposition, upper extension (290) of knife member (280) is positionedabove engagement features (222, 224) of frame member (238). As knifemember (280) is fired distally, because resilient member (210) is notbearing upon knife member (280), knife member (280) maintains itsvertical position. Because knife member (280) maintains its verticalposition, tab (298) of knife member (280) translates distally aboveengagement features (222, 224) of frame member (238) such that resilientmember (210) does not drive tab (298) downwardly between engagementfeatures (222, 224) to prevent the distal movement of knife member(280).

V. Exemplary Cartridge Seating Features

In some instances, it may be desirable to provide features that promoteproper seating of a staple cartridge (70, 270) within lower jaws (50,250). For example, such a feature may provide for proper engagement ofthe cartridge staple cartridge (70, 270) within lower jaws (50, 250)and/or proper alignment of the staple cartridge (70, 270) relative tolower jaws (50, 250). Further, such a feature may be configured toretain a position of the staple cartridge (70, 270) within lower jaws(50, 250) during operation. The examples described below include severalmerely illustrative versions of seating features that may be readilyintroduced to end effectors (40, 240) and/or staple cartridges (70,270). The examples described below may be viewed as “poka-yoke” featuresthat represent exemplary alternatives to the “poka-yoke” featuresdisclosed in U.S. patent application Ser. No. 13/780,417, entitled“Installation Features for Surgical Instrument End Effector Cartridge,”filed Feb. 28, 2013, the disclosure of which is incorporated byreference herein.

A. Exemplary Anvil with Engagement Features

FIGS. 65-67B show an exemplary alternative anvil (500) having a seatingfeature. Anvil (500) may be readily incorporated into end effectors (40,240) in place of anvils (60, 260). Anvil (500) of the present example isconfigured to operate substantially similar to anvils (60, 260)discussed above except for the differences discussed below. The seatingfeature of the present example comprises a pair of protrusions (502,504). Protrusions (502, 504) of the present example extend downwardlyfrom a proximal portion of an underside of anvil (500) but may extendfrom any other appropriate portion of anvil (500). Protrusions (502,504) are positioned on opposite lateral sides adjacent to a channel(506) formed in anvil (500). Channel (506) is substantially identical tochannel (62) described above.

Protrusions (502, 504) of the present example each define a parabolicshape. Although protrusions (502, 504) of the present example comprise aparabolic shape, protrusions (502, 504) may comprise any otherappropriate shape. With anvil (500) in an open position as shown in FIG.67A, cartridge (70) may be received within lower jaw (50, 250). As anvil(500) is pivoted toward lower jaw (50, 250) into a closed position asshown in FIG. 67B, protrusions (502, 504) are configured to bear againsta top surface of a proximal portion of cartridge (70) so as to drivecartridge (70) downwardly into lower jaw (50, 250) to thereby providefor proper seating of cartridge (70) within lower jaw (50, 250). Itshould therefore be appreciated that if an operator fails to fully presscartridge (70) into lower jaw (50, 250) when the operator placescartridge (70) in lower jaw (50, 250), anvil (500) will fully presscartridge (70) into lower jaw (50, 250) during closure of anvil (500).Thus, before positioning tissue between anvil (500) and lower jaw (50,250), the operator may close anvil (500) to ensure proper seating ofcartridge (70), then open anvil (500) such that end effector (40, 240)is able to capture tissue. Although anvil (500) is shown and describedas being used with cartridge (70) in the present example, it should beunderstood that anvil (500) may also be used with any cartridge (270,300, 320, 340, 360, 400, 410, 450, 460, 470) discussed herein.

B. Exemplary Anvil and Cartridge with Alignment Features

FIGS. 68-71 show another exemplary alternative anvil (520) and staplecartridge (530) having mating seating features. Anvil (520) andcartridge (530) may be readily incorporated into end effectors (40, 240)in place of anvils (60, 260) and/or cartridges (270, 300, 320, 340, 360,400, 410, 450, 460, 470). Anvil (520) of the present example isconfigured to operate substantially similar to anvils (60, 260)discussed above except for the differences discussed below. Cartridge(530) of the present example is configured to operate substantiallysimilar to cartridges (70, 270) discussed above except for thedifferences discussed below. As best seen in FIG. 68, the seatingfeatures of anvil (520) of the present example comprise a pair ofprotrusions (522, 524). Protrusions (522, 524) of the present exampleextend downwardly from a proximal portion of an underside of anvil (520)but may extend from any other appropriate portion of anvil (520).Protrusions (522, 524) are positioned on opposite lateral sides adjacentto a channel (526) formed in anvil (520). Channel (526) is substantiallyidentical to channel (62) described above.

As best seen in FIG. 69, the seating features of cartridge (530) of thepresent example comprise a pair of recesses (532, 534). Recesses (532,534) of the present example are formed in a proximal portion of a topsurface of cartridge (530) but may be formed in any other appropriateportion of cartridge (530). Recesses (532, 534) are positioned onopposite lateral sides adjacent to a channel (536) formed in cartridge(530). Channel (536) is substantially identical to channel (72)described above. Protrusions (522, 524) and recesses (532, 534) havecomplementary shapes such that recesses (532, 534) are configured toreceive protrusions (522, 524). Protrusions (522, 524) and recesses(532, 534) of the present example each have a parabolic shape. Althoughprotrusions (522, 524) and recesses (532, 534) of the present examplecomprise a parabolic shape, protrusions (522, 524) and recesses (532,534) may comprise any other appropriate share.

With anvil (520) in an open position, cartridge (530) may be receivedwithin lower jaw (50, 250). As anvil (520) is pivoted toward lower jaw(50, 250) into a partially closed position as shown in FIG. 70A,recesses (532, 534) of cartridge (530) initially receive protrusions(522, 524) of anvil (520). As anvil (520) is further pivoted towardlower jaw (50, 250) into a closed position as shown in FIGS. 70B and 71,recesses (532, 534) of cartridge (530) completely receive protrusions(522, 524) of anvil (520). As recesses (532, 534) receive protrusions(522, 524), engagement between recesses (532, 534) and protrusions (522,524) will cause recesses (532, 534) to become aligned with protrusions(522, 524) to thereby laterally and longitudinally align cartridge (530)within lower jaw (50, 250). Thus, as anvil (520) is pivoted into theclosed position, this motion will cause proper lateral and longitudinalalignment of cartridge (530). It should also be appreciated thatprotrusions (522, 524) and recesses (532, 534) cooperate to provideproper vertical positioning of cartridge (530) in lower jaw (50, 250) inaddition to providing proper longitudinal and lateral positioning ofcartridge (530) in lower jaw (50, 250). In particular, protrusions (522,524) may further be configured to bear against a surface within recesses(532, 534) so as to drive cartridge (530) downwardly into lower jaw (50,250) to thereby provide for proper seating of the cartridge within lowerjaw (50, 250).

C. Exemplary Cartridge Body and Tray with Engagement Features

FIGS. 72-77 show an exemplary staple cartridge (540) and a lower jaw(550) having mating engagement features. Cartridge (540) and lower jaw(550) may be readily incorporated into end effectors (40, 240) in placeof cartridges (270, 300, 320, 340, 360, 400, 410, 450, 460, 470) and/orlower jaws (50, 250) discussed above. Cartridge (540) of the presentexample is configured to operate substantially similar to cartridges(70, 270) discussed above except for the differences discussed below.Lower jaw (550) of the present example is configured to operatesubstantially similar to lower jaws (50, 250) discussed above except forthe differences discussed below. The engagement features of cartridge(540) of the present example comprise a pair of angled protrusions (542,544). Protrusions (542, 544) of the present example extend outwardlyfrom a proximal portion of opposing exterior surfaces of cartridge (540)but may extend from any other appropriate portion of cartridge (540).The engagement features of lower jaw (550) of the present examplecomprise a pair of slots (552, 554). Slots (552, 554) are configured tomatingly receive protrusions (542, 544) so as to provide for properlongitudinal alignment between cartridge (540) and lower jaw (550).Protrusions (542, 544) of the present example are angled upwardly andoutwardly such that as cartridge (540) is inserted into lower jaw (550),lower jaw (550) will flare outwardly such that cartridge (540) may bereceived within lower jaw (550) and such that protrusions (542, 544) maybe received within slots (552, 554). With protrusions (542, 544) engagedwith slots (552, 554), cartridge (540) and lower jaw (550) are coupledtogether so as to ensure proper engagement between cartridge (540) andlower jaw (550).

D. Exemplary Cartridge and Lower Jaw with Alignment Features

FIGS. 78-86 show another exemplary alternative cartridge (560) and lowerjaw (570) having mating alignment features. Cartridge (560) and lowerjaw (570) may be readily incorporated into end effectors (40, 240) inplace of cartridges (270, 300, 320, 340, 360, 400, 410, 450, 460, 470)and/or lower jaws (50, 250) discussed above. Cartridge (560) of thepresent example is configured to operate substantially similar tocartridges (70, 270) discussed above except for the differencesdiscussed below. Lower jaw (570) of the present example is configured tooperate substantially similar to lower jaws (50, 250) discussed aboveexcept for the differences discussed below. As best seen in FIGS. 78-80,the alignment features of cartridge (560) of the present examplecomprise a pair of rigid protrusions (562, 564) extending proximallyfrom a proximal end of cartridge (560). As best seen in FIGS. 81-83, thealignment features of lower jaw (570) of the present example comprise apair of rigid protrusions (572, 574) extending inwardly from opposinginterior surfaces of cartridge (570). Lower jaw (570) is configured toreceive cartridge (560).

As shown in FIGS. 84-86, with cartridge (560) disposed within lower jaw(570), protrusions (562, 564) of cartridge (560) are aligned belowprotrusions (572, 574) of lower jaw (570) so as to ensure propervertical alignment between cartridge (560) and lower jaw (570). Ascartridge (560) is inserted into lower jaw (570), an operator firstinserts the proximal end of cartridge (560) into lower jaw (570) suchthat protrusions (562, 564) are positioned below protrusions (572, 574)of lower jaw (570). At this point, the operator pivots a distal end ofcartridge (560) into a distal end of lower jaw (570) such that cartridge(560) is completely engaged with lower jaw (570). As the distal end ofcartridge (560) is pivoted into lower jaw (570), the positioning ofprotrusions (562, 564) of cartridge (560) below protrusions (572, 574)of lower jaw (570) will maintain the vertical alignment of the proximalend of cartridge (560). It should be understood that protrusions (572,574) of lower jaw (570) may be downwardly biased so as to furtherprovide for proper vertical alignment between cartridge (560) and lowerjaw (570).

E. Exemplary Wedge Sled and Lower Jaw with Alignment Features

FIGS. 87-95 show an exemplary alternative wedge sled (580) havingalignment features configured to matingly engage with lower jaw (570)discussed above. Sled (580) of the present example may be readilyincorporated into staple cartridge (70) or any other staple cartridgedescribed herein. Sled (580) of the present example is configured tooperate substantially similar to sleds (78, 278) discussed above exceptfor the differences discussed below. For instance, as with sleds (78,278) discussed above, sled (580) of the present example is capturedbetween a cartridge body and a cartridge tray of a cartridge and isoperable to translate longitudinally the through cartridge body. Itshould be understood that sled (580) of the present example may be usedwith any appropriate cartridge discussed herein. As best seen in FIGS.87-89, the alignment features of sled (580) of the present examplecomprise a pair of rigid protrusions (582, 584) extending proximallyfrom a proximal end of sled (580). As shown in FIGS. 90-92, when sled(580) is in an initial position (a position prior to being fireddistally), protrusions (582, 584) extend proximally from a proximal endof cartridge (70). As shown in FIGS. 93-95, with cartridge (70) disposedwithin lower jaw (570), protrusions (582, 584) of sled (580) are alignedbelow protrusions (572, 574) of lower jaw (570) so as to ensure propervertical alignment between cartridge (70) and lower jaw (570). It shouldbe understood that upon firing of sled (580) distally, protrusions (582,584) would no longer be aligned with protrusions (572, 574) of lower jaw(570). As cartridge (70), with sled (580), is inserted into lower jaw(570), an operator first inserts the proximal end of cartridge (70) intolower jaw (570) such that protrusions (582, 584) are positioned belowprotrusions (572, 574) of lower jaw (570). At this point, the operatorpivots a distal end of cartridge (70) into a distal end of lower jaw(570) such that cartridge (70) is completely engaged with lower jaw(570). As the distal end of cartridge (70) is pivoted into lower jaw(570), the positioning of protrusions (582, 584) of sled (580) belowprotrusions (572, 574) of lower jaw (570) will maintain the verticalalignment of the proximal end of cartridge (70). It should also beunderstood that protrusions (572, 574) of lower jaw (570) may bedownwardly biased so as to further provide for proper vertical alignmentbetween cartridge (70) and lower jaw (570).

F. Exemplary Cartridge Tray with Resilient Tab Engagement Features

FIGS. 96-98 show another exemplary cartridge tray (590) with engagementfeatures. Cartridge tray (590) of the present example may be readilyincorporated into staple cartridge (70) or any other staple cartridgedescribed herein. Cartridge tray (590) of the present example isconfigured to operate substantially similar to cartridge trays (76, 276)discussed above except for the differences discussed below. Theengagement features of cartridge tray (590) of the present examplecomprise a pair of resilient tabs (592, 594) extending upwardly andinwardly from a proximal end of cartridge tray (590). It should beunderstood that cartridge tray (590) of the present example may be usedwith any appropriate cartridge discussed herein. As shown in FIGS. 97and 98, with cartridge (70) having cartridge tray (590) disposed withinlower jaw (50, 250), tabs (592, 594) of cartridge tray (590) engage apair of inwardly extending tabs (51, 53, 251, 253) of lower jaw (50,250). As best seen in FIG. 98, with cartridge (70) disposed within lowerjaw (50, 250), tabs (51, 53, 251, 253) of lower jaw (50, 250) areconfigured to bear against a top surface of tabs (592, 294) of cartridgetray (590) to thereby drive cartridge (70) downwardly within lower jaw(50, 250) so as to ensure proper engagement between cartridge (70) andlower jaw (50, 250).

G. Exemplary Cartridge Tray with Leaf Spring Engagement Features

FIGS. 99-101 show another exemplary cartridge tray (600) with engagementfeatures. Cartridge tray (600) of the present example may be readilyincorporated into staple cartridge (70) or any other staple cartridgedescribed herein. Cartridge tray (600) of the present example isconfigured to operate substantially similar to cartridge trays (76, 276)discussed above except for the differences discussed below. As shown inFIGS. 99 and 100, the engagement features of cartridge tray (600) of thepresent example comprise a pair of resilient members (602, 604)extending proximally from a proximal end of cartridge tray (600).Resilient members (602,604) are configured as leaf springs in thepresent example. It should be understood that cartridge tray (600) ofthe present example may be used with any appropriate cartridge discussedherein. As shown in FIG. 101, with cartridge (70) having cartridge tray(600) disposed within lower jaw (250), resilient members (602, 604) ofcartridge tray (600) engage a bottom surface (241) of frame member(238). (It should be noted that the cross-sectional view of FIG. 101 istaken along a plane that is laterally offset from a longitudinal axis ofend effector (240).) With cartridge (70) disposed within lower jaw(250), resilient members (602, 604) are configured to bear against thebottom surface (241) of frame member (238) to thereby drive cartridge(70) downwardly within lower jaw (250) so as to ensure proper engagementbetween cartridge (70) and lower jaw (250).

H. Exemplary Cartridge Tray with Resilient Engagement and RetainingFeatures

FIGS. 102-106 show an exemplary cartridge tray (610) with engagement andretaining features. Cartridge tray (610) of the present example may bereadily incorporated into staple cartridge (70) or any other staplecartridge described herein. Cartridge tray (610) of the present exampleis configured to operate substantially similar to cartridge trays (76,276) discussed above except for the differences discussed below. As bestseen in FIGS. 102 and 103, the engagement and retaining features ofcartridge tray (610) of the present example comprise a pair of resilientcurved members (612, 614) curved upwardly and extending proximally froma proximal end of cartridge tray (590). It should be understood thatcartridge tray (610) of the present example may be used with anyappropriate cartridge discussed herein. As shown in FIGS. 104-106, withcartridge (70) having cartridge tray (610) disposed within lower jaw(50, 250), curved members (612, 614) of cartridge tray (610) engageinwardly extending tabs (51, 53, 251, 253) of lower jaw (50, 250). Asbest seen in FIGS. 104 and 105, as cartridge (70) is inserted into lowerjaw (50, 250), this engagement is configured to bend curved members(612, 614) distally and fold curved members (612, 614) down upon a topsurface of a proximal portion of cartridge (70) so as to ensure properengagement between cartridge (70) and lower jaw (50, 250) and so as toretain engagement between cartridge (70) and lower jaw (50, 250).

VI. Anvil Alignment Features

In some instances, it may be desirable to provide alignment featuresthat ensure that anvil (60, 260) will be clamped squarely relative tostaple cartridge (70, 270). For instance, in some end effectors (40,240), manufacturing tolerances may result in a tendency for anvil (60,260) to be mis-aligned relative to staple cartridge (70, 270). Suchmis-alignment may include a deflection of anvil (60, 260) laterally awayfrom a vertical plane extending along the central longitudinal axis ofstaple cartridge (70, 270). Such mis-alignment may also include a rolldeflection of anvil (60, 260) about the central longitudinal axis ofstaple cartridge (70, 270). In some cases, such mis-alignment mayfurther include longitudinal mis-alignment of anvil (60, 260) relativeto staple cartridge (70, 270). Alignment features may be used to addressmanufacturing tolerances to thereby correct lateral deflections, rolldeflections, longitudinal deflections, and/or other deflections of anvil(60, 260) relative to staple cartridge (270).

It may also be desirable to provide alignment features that ensure thatanvil (60, 260) will define an appropriate gap with staple cartridge(70, 270) when anvil (60, 260) is brought to the fully closed position.Such features may prevent anvil (60, 260) from being closed too firmlyon tissue captured between anvil (60, 260) and staple cartridge (70,270). Such features may also provide a consistent location for wherepre-loading of anvil (60, 260) occurs against staple cartridge (70, 270)for each closure stroke of anvil (70, 270).

Various kinds of alignment and/or gap-setting features may be providedin anvil (60, 260), in cartridge (70, 270), or in both. Examples of suchalignment or gap-setting features are disclosed in U.S. patentapplication Ser. No. 13/780,106, entitled “Integrated Tissue Positioningand Jaw Alignment Features for Surgical Stapler,” filed Feb. 28, 2013,the disclosure of which is incorporated by reference herein. Furtherexamples of alignment and/or gap-setting features may be provided inanvil (60, 260), in cartridge (70, 270) are described in greater detailbelow, while still other examples will be apparent to those of ordinaryskill in the art in view of the teachings herein.

A. Exemplary Cartridge and Anvil with Cylindrical Alignment andGap-Setting Features

FIGS. 107-109 show an exemplary alternative cartridge (620) and anvil(630) having alignment and gap-setting features. Cartridge (620) andanvil (630) may be readily incorporated into end effectors (40, 240) inplace of cartridges (270, 300, 320, 340, 360, 400, 410, 450, 460, 470)and/or anvils (60, 260). Cartridge (620) of the present example isconfigured to operate substantially similar to cartridges (70, 270)discussed above except for the differences discussed below. Anvil (630)of the present example is configured to operate substantially similar toanvils (60, 260) discussed above except for the differences discussedbelow. As best seen in FIG. 107, the alignment and gap-setting featuresof cartridge (620) of the present example comprise a pair of cylindricalprotrusions (622, 624) extending upwardly from a top surface of a distalportion of cartridge (620). As best seen in FIG. 108, the alignment andgap-setting features of anvil (630) of the present example comprise apair of cylindrical recesses (632, 634) formed in an underside of adistal portion of anvil (630). Recesses (632, 634) are sized and shapedto complement the size and shape of protrusions (622, 624). In somevariations, recesses (632, 634) are formed in anvil (630) whileprotrusions (622, 624) are part of cartridge (620).

As shown in FIG. 109, upon closure of anvil (630), cylindrical recesses(632, 634) are configured to receive cylindrical protrusions (622, 624)to thereby ensure proper lateral, roll, and/or longitudinal alignment ofanvil (630) relative to cartridge (620). Furthermore, a depth ofcylindrical recesses (632, 634) and a height of cylindrical protrusions(622, 624) are such that upon proper closure, a top surface ofcylindrical protrusions (622, 624) will contact a bottom surface ofcylindrical recesses (632, 634) to thereby prevent further closure so asto maintain a proper distance between anvil (630) and cartridge (620)(i.e., protrusions (622, 624) and recesses (632, 634) establish aminimum gap distance between a top surface of cartridge (620) and anvil(630) so as to prevent over-compression of tissue). It should also beunderstood that protrusions (622, 624) may provide a depth stop torestrict insertion of the distal end of cartridge (620) in a catheter.Likewise, in versions where protrusions (622, 624) are part of anvil(630), protrusions (622, 624) may provide a depth stop to restrictinsertion of the distal end of anvil (630) in a catheter. By way ofexample only, an operator may wish to position the end of a catheter onthe distal end of anvil (630) or cartridge (620) in order to use anvil(630) or cartridge (620) to position the catheter in relation to ananatomical structure in the patient.

B. Exemplary Cartridge and Anvil with Conical Alignment and Gap-SettingFeatures

FIGS. 110-113 show an exemplary alternative cartridge (640) and anvil(650) having alignment and gap-setting features. Cartridge (640) andanvil (650) may be readily incorporated into end effectors (40, 240) inplace of cartridges (270, 300, 320, 340, 360, 400, 410, 450, 460, 470)and/or anvils (60, 260). Cartridge (640) of the present example isconfigured to operate substantially similar to cartridges (70, 270)discussed above except for the differences discussed below. Anvil (650)of the present example is configured to operate substantially similar toanvils (60, 260) discussed above except for the differences discussedbelow. As best seen in FIGS. 110 and 111, the alignment and gap-settingfeatures of cartridge (640) of the present example comprise a pair ofrounded conical protrusions (642, 644) extending upwardly from a topsurface of a distal portion of cartridge (640). As best seen in FIG.112, the alignment and gap-setting features of anvil (650) of thepresent example comprise a pair of spherical recesses (652, 654) formedin an underside of a distal portion of anvil (650). Recesses (652, 654)are sized and shaped to complement the size and shape of protrusions(642, 644). In some variations, recesses (652, 654) are formed in anvil(630) while protrusions (642, 644) are part of cartridge (640).

As shown in FIG. 113, upon closure of anvil (650), spherical recesses(652, 654) are configured to receive conical protrusions (642, 644) tothereby ensure proper lateral, roll, and/or longitudinal alignment ofanvil (650) relative to cartridge (640). Furthermore, a depth ofspherical recesses (652, 654) and a height of conical protrusions (642,644) are such that upon proper closure, a top surface of conicalprotrusions (642, 644) will contact a bottom surface of sphericalrecesses (652, 654) to thereby prevent further closure so as to maintaina proper distance between anvil (650) and cartridge (640) (i.e.,protrusions (642, 644) and recesses (652, 654) establish a minimum gapdistance between a top surface of cartridge (640) and anvil (650) so asto prevent over-compression of tissue). It should also be understoodthat protrusions (642, 644) may provide a depth stop to restrictinsertion of the distal end of cartridge (640) in a catheter. Likewise,in versions where protrusions (642, 644) are part of anvil (650),protrusions (642, 644) may provide a depth stop to restrict insertion ofthe distal end of anvil (650) in a catheter. By way of example only, anoperator may wish to position the end of a catheter on the distal end ofanvil (650) or cartridge (640) in order to use anvil (650) or cartridge(640) to position the catheter in relation to an anatomical structure inthe patient.

C. Exemplary Cartridge and Anvil with Rectangular Alignment andGap-Setting Features

FIGS. 114-117 show an exemplary alternative cartridge (660) and anvil(670) having alignment and gap-setting features. Cartridge (660) andanvil (670) may be readily incorporated into end effectors (40, 240) inplace of cartridges (270, 300, 320, 340, 360, 400, 410, 450, 460, 470)and/or anvils (60, 260). Cartridge (660) of the present example isconfigured to operate substantially similar to cartridges (70, 270)discussed above except for the differences discussed below. Anvil (670)of the present example is configured to operate substantially similar toanvils (60, 260) discussed above except for the differences discussedbelow. As best seen in FIGS. 114 and 115, the alignment and gap-settingfeatures of cartridge (660) of the present example comprise a pair ofrectangular protrusions (662, 664) extending upwardly from a top surfaceof a distal portion of cartridge (660). As best seen in FIG. 116, thealignment and gap-setting features of anvil (670) of the present examplecomprise a pair of rectangular recesses (672, 674) formed in anunderside of a distal portion of anvil (670). Recesses (672, 674) aresized and shaped to complement the size and shape of protrusions (662,664). In some variations, recesses (672, 674) are formed in anvil (670)while protrusions (662, 664) are part of cartridge (660).

As shown in FIG. 113, upon closure of anvil (670), rectangular recesses(672, 674) are configured to receive rectangular protrusions (662, 664)to thereby ensure proper lateral, roll, and/or longitudinal alignment ofanvil (670) relative to cartridge (660). Furthermore, a depth ofrectangular recesses (672, 674) and a height of rectangular protrusions(662, 664) are such that upon proper closure, a top surface ofrectangular protrusions (662, 664) will contact a bottom surface ofrectangular recesses (672, 674) to thereby prevent further closure so asto maintain a proper distance between anvil (670) and cartridge (660)(i.e., protrusions (662, 664) and recesses (672, 674) establish aminimum gap distance between a top surface of cartridge (660) and anvil(670) so as to prevent over-compression of tissue). It should also beunderstood that protrusions (662, 664) may provide a depth stop torestrict insertion of the distal end of cartridge (660) in a catheter.Likewise, in versions where protrusions (662, 664) are part of anvil(670), protrusions (662, 664) may provide a depth stop to restrictinsertion of the distal end of anvil (670) in a catheter. By way ofexample only, an operator may wish to position the end of a catheter onthe distal end of anvil (670) or cartridge (660) in order to use anvil(670) or cartridge (660) to position the catheter in relation to ananatomical structure in the patient.

VII. Exemplary Features to Prevent Use of Staple Cartridge in IncorrectEnd Effector

Various surgical stapling instruments are available for purchase anduse. These various surgical stapling instruments may use differentstaple cartridges. In some instances, an operator may have difficulty inimmediately discerning which staple cartridge corresponds to whichsurgical stapling instrument. An operator may therefore inadvertentlyplace and attempt to use a staple cartridge in an incorrect surgicalstapling device. Thus, it may be desirable to provide features thatprevent a staple cartridge that is intended to be used in one particularsurgical stapling instrument from being used in other, incorrectsurgical stapling instruments. For instance, such features may preventinsertion of an improper staple cartridge and/or may prevent firing of aknife member or a firing beam in the presence of an incorrect staplecartridge. The example below includes merely illustrative versions offeatures that may be readily introduced to any of the cartridges (70,270, 300, 320, 340, 360, 400, 410, 450, 460, 470) discussed above.

A. Exemplary End Effector with “E-Beam”

Some surgical stapling instruments may include an “E-Beam” type of knifemember or firing beam, instead of including a structure like thecombination of knife member (80, 280) and firing beam (82, 282)described above. An example of such a stapling instrument (710) is shownin FIGS. 118-128. Instrument (710) comprises an end effector (740)having an E-beam firing mechanism (“firing bar”) (714) that controls thespacing of the end effector (740). In particular, a lower jaw (716) anda pivotally translatable anvil (760) are maintained at a spacing thatassures effective stapling and cutting.

Instrument (710) includes a handle portion (720) connected to a shaftassembly (722), shaft assembly (722) comprising a shaft (723) distallyterminating in end effector (740). Handle portion (720) includes apistol grip (724) toward which a closure trigger (726) is pivotallydrawn by the operator to cause clamping, or closing, of anvil (760)toward lower jaw (716) of end effector (740). A firing trigger (728) isfarther outboard of closure trigger (726) and is pivotally drawn by theoperator to cause the stapling and cutting of clamped tissue in endeffector (740). A closure sleeve (732) encloses a frame (734), which inturn encloses a firing drive member (736) that is positioned by firingtrigger (728). Frame (734) connects handle portion (720) to end effector(740). With closure sleeve (732) withdrawn proximally by closure trigger(726) as depicted, anvil (760) springedly opens, pivoting away fromlower jaw (716) and translating proximally with closure sleeve (732).

As shown in FIGS. 119-121, firing bar (714) includes three verticallyspaced pins (738, 744, 746) that control the spacing of end effector(740) during firing. In particular, an upper pin (738) is staged toenter an anvil pocket (716) near the pivot between anvil (760) and lowerjaw (716). When fired with anvil (760) closed, the upper pin (738)advances distally within a longitudinal anvil slot (742) extendingdistally through anvil (760). Any minor upward deflection in anvil (760)is overcome by a downward force imparted by upper pin (738). Firing bar(714) also includes a lower most pin, or firing bar cap (744), thatupwardly engages a channel slot (745) in lower jaw (716), therebycooperating with upper pin (738) to draw anvil (760) and lower jaw (716)slightly closer together in the event of excess tissue clampedtherebetween.

Firing bar (714) further includes a middle pin (746) that passes througha firing drive slot (747) formed in a lower surface of cartridge (770)and an upward surface of lower jaw (716), thereby driving the staplestherein. Middle pin (746), by sliding against lower jaw (716), resistsany tendency for end effector (740) to be pinched shut at its distalend. A distally presented cutting edge (748) between upper and middlepins (738, 746) on firing bar (714) traverses through a proximallypresented, vertical slot (749) in cartridge (770) to cut clamped tissue.The affirmative positioning of firing bar (714) with regard to lower jaw(716) and anvil (760) assure that an effective cut is performed.

An exemplary use of instrument (710) is depicted in FIGS. 118, 119, and122-128. In FIGS. 118 and 119, instrument (710) is in its startposition, having had an unfired, fully loaded staple cartridge (770)snap-fitted into the distal end of lower jaw (716). Both triggers (726,728) are forward and end effector (740) is open. Instrument (710) isthen manipulated by the operator such that tissue to be stapled andsevered is positioned between staple cartridge (770) and anvil (760), asdepicted in FIG. 122. As shown in FIGS. 123 and 124, the operator movesclosure trigger (726) proximally until positioned directly adjacent topistol grip (724). With anvil (760) closed and clamped, firing bar (714)is aligned for firing through end effector (740). In particular, upperpin (738) is aligned with anvil slot (742) and lower jaw (716) isaffirmatively engaged about channel slot (745) by middle pin (746) andfiring bar cap (744).

As shown in FIGS. 125 and 126, after tissue clamping has occurred, theoperator moves firing trigger (728) proximally causing firing bar (714)to move distally into end effector (740). In particular, middle pin(746) enters staple cartridge (770) through firing drive slot (747) toeffect firing of staples (790) (not shown in FIGS. 125 and 126) via awedge sled (778) toward anvil (760). Lower most pin, or firing bar cap(744), cooperates with middle pin (746) to slidingly position cuttingedge (748) of firing bar (714) to cut tissue. The two pins (744, 746)also position upper pin (738) of firing bar (714) within longitudinalanvil slot (742) of anvil (760), affirmatively maintaining the spacingbetween anvil (760) and lower jaw (716) throughout its distal firingmovement.

With reference to FIGS. 127 and 128, the operator continues movingfiring trigger (728) until brought proximal to closure trigger (726) andpistol grip (724). Thereby, all of the ends of staples (790) are bentover as a result of their engagement with anvil (760). Firing bar cap(744) is arrested against a firing bar stop (792) projecting toward thedistal end of channel slot (745). Cutting edge (748) has traversedcompletely through the tissue.

It should be understood that instrument (710) of the present example maybe further constructed and/or operable in accordance with at least someof the teachings of U.S. Pat. No. 7,380,695, entitled “Surgical StaplingInstrument Having a Single Lockout Mechanism for Prevention of Firing,”issued Jun. 3, 2008, the disclosure of which is incorporated byreference herein.

B. Exemplary Lockout to Prevent Use of Staple Cartridge in E-Beam EndEffector

In some instances, it may be desirable to provide lockout features thatprevent firing of firing bar (714) of instrument (710) if aninappropriate staple cartridge is inserted into end effector (740).Accordingly, lockout features may be provided on a staple cartridge thatis not intended to be used with instrument (710) to thereby preventfiring of firing bar (714).

FIGS. 129-134 show an exemplary alternative cartridge tray (800) havinglockout features. Cartridge tray (800) is incorporated into a staplecartridge (810) (FIG. 132) that is intended for use in end effector (40,240) but not in end effector (740). Cartridge tray (800) of the presentexample is configured to operate substantially similar to cartridgetrays (76, 276) discussed above except for the differences discussedbelow. As best seen in FIGS. 129-131, the lockout features of cartridgetray (800) of the present example comprise a pair of rigid tabs (802,804) extending upwardly from a proximal end of a top surface of a baseof cartridge tray (800). As shown in FIGS. 132 and 133, with a cartridgebody (806) disposed within cartridge tray (800), tabs (802, 804) arepositioned proximally of a proximal end of cartridge body (806). Asshown in FIG. 134, tabs (802, 804) are configured to engage middle pin(746) so as to prevent distal firing of firing bar (714) in the eventthat cartridge (810) having cartridge tray (800) is inserted into lowerjaw (716). Thus, tabs (802, 804) prevent cartridge (810) from being usedin end effector (740). However, tabs (802, 804) do not prevent cartridge(810) from being used in end effectors (40, 240). End effectors (40,240) include no moving components whose movement would be blocked bytabs (802, 804).

VIII. Exemplary Alternative Lockout Features

FIGS. 135-139 show features of an exemplary alternative end effector(1000) that may be used in place of any of the end effectors (40, 240)described herein. End effector (1000) of this example comprises an anvil(1010), a staple cartridge (1012), a lower jaw (1020), and a knifemember (1040). Anvil (1010) of this example is identical to anvils (60,260) described above. Similarly, staple cartridge (1012) of this exampleis identical to staple cartridges (70, 270) described above. It shouldbe understood that end effector (1000) may be readily incorporated intoinstrument (10) in place of end effector (40, 240).

As best seen in FIGS. 135-136, knife member (1040) of the presentexample is substantially identical to knife members (80, 280) describedabove, except for the differences described below. Knife member (1040)of this example includes a distal cutting edge (1042), a distal tip(1044), a downwardly extending protrusion (1046), and a firing beamengagement feature (1052). Protrusion (1046) includes a distally facinglockout surface (1048), which will be described in greater detail below.An upwardly extending tab (1050) is located at the proximal end ofprotrusion (1046). As best seen in FIGS. 138-139, firing beam engagementfeature (1052) is configured to couple with a complementary engagingfeature (1062) of a firing beam (1060). Such coupling may be securedusing welding (e.g., spot welds, etc.), adhesives, and/or any othersuitable techniques/features/etc. It should also be understood that thecombination of firing beam (1060) and knife member (1040) may betranslated distally and proximally using the same features andtechniques described above with respect to firing beam (82, 282). Othersuitable ways in which the combination of firing beam (1060) and knifemember (1040) may be translated distally and proximally will be apparentto those of ordinary skill in the art in view of the teachings herein.

FIG. 137 shows lower jaw (1020) of the present example in greaterdetail. Lower jaw (1020) is substantially identical to lower jaws (50,250) described above, except for the differences described below. Lowerjaw (1020) is configured to removably receive staple cartridge (1012) asshown in FIGS. 138-139. Lower jaw (1020) is also pivotably coupled withanvil (1010), such that anvil (1010) is operable to pivot toward andaway from the combination of staple cartridge (1012) and lower jaw(1020), as described in other examples above. Turning back to FIG. 137,lower jaw (1020) of this example includes a proximal slot (1022). Thedistal end of slot (1022) terminates at a proximally facing lockoutsurface (1024). As will be described in greater detail below, lockoutsurface (1048) of knife member (1040) is configured to engage lockoutsurface (1024) of lower jaw (1020) in order to provide a lockoutcondition when either staple cartridge (1012) has already been firedonce or staple cartridge (1012) is missing.

FIG. 138 shows end effector (1000) in a ready to fire state. Inparticular, staple cartridge (1012) is loaded in lower jaw (1020), anvil(1010) is in a closed position, and knife member (1040) is in a proximalposition. In this state, knife member (1040) is also in an upperposition. Knife member (1040) is positioned such that a portion of knifemember (1040) is disposed in an opening (1084) of a resilient member(1080). Resilient member (1080) of this example is identical toresilient member (210) described above. In this state, a distal end(1082) is positioned above protrusion (1046) and distal to tab (1050).Resilient member (1080) resiliently bears downwardly on knife member(1040) in this state. However, distal tip (1044) of knife member (1040)engages an upwardly facing surface at the proximal end of a sled (1014)in staple cartridge (1012). Sled (1014) thus cooperates with distal tip(1044) to provide support for knife member (1040), holding knife member(1040) in the upper position despite the downward bias imposed byresilient member (1080). It should be noted that lockout surface (1048)of knife member (1040) is located at a vertical position that is higherthan the vertical position of lockout surface (1024) in this state. Sled(1014) of this example is substantially identical to sleds (78, 278)described above.

As firing beam (1060) and knife member (1040) are advanced distally fromthe position shown in FIG. 138 to actuate end effector (1000), drivingstaples from staple cartridge (1012) into tissue and severing the tissuewith edge (1042), sled (1014) continues to cooperate with distal tip(1044) to provide support for knife member (1040). Knife member (1040)thus maintains the vertical positioning shown in FIG. 138 as knifemember (1040) translates from a proximal position to a distal position.It should therefore be understood that lockout surface (1048) of knifemember (1040) passes over lockout surface (1024) of lower jaw (1020),such that lockout surface (1048) does not engage lockout surface (1024)during the distal translation of knife member (1040) when sled (1014)provides support for knife member (1040). It should also be understoodthat, in the present example, sled (1014) will only provide support forknife member (1040) when cartridge (1012) has been properly loaded inlower jaw (1020) and cartridge (1012) has not yet been fired.

In the event that cartridge (1012) is not loaded in lower jaw (1020),lockout surface (1048) of knife member (1040) will engage lockoutsurface (1024) of lower jaw (1020), thereby effectively locking knifemember (1040) by preventing further distal translation of knife member(1040). Similarly, in the event that an operator attempts to drive knifemember (1040) distally after cartridge (1012) has been fired (or evenpartially fired), lockout surface (1048) of knife member (1040) willengage lockout surface (1024) of lower jaw (1020), thereby effectivelylocking knife member (1040) by preventing further distal translation ofknife member (1040). For instance, FIG. 139 shows end effector (1000) ina state where sled (1014) is positioned distally in relation to theposition of sled (1014) in FIG. 138. Sled (1014) is thus spaced awayfrom distal tip (1044), such that sled (1014) will not provide supportfor knife member (1040). Without the support of sled (1014), resilientmember (1080) drives knife member (1040) downwardly as knife member(1040) is advanced distally. This causes lockout surface (1048) of knifemember (1040) to engage lockout surface (1024) of lower jaw (1020), asshown in FIG. 139. With surfaces (1048, 1024) so engaged, knife member(1040) may not be translated any further distally.

If the operator subsequently retracts knife member (1040) proximallyfrom the position shown in FIG. 139, a camming feature in end effector(1000) may drive knife member (1040) upwardly, such that knife member(1040) and resilient member (1080) return to the positions shown in FIG.138. This may enable the operator to load an unfired staple cartridge(1012) in end effector (1000) and actuate end effector (1000) properly.

It should be understood from the foregoing that the lockout features oflower jaw (1020) and knife member (1040) may serve as a substitute forthe lockout features of frame member (238) and knife member (280)described above. It should also be understood that the various kinds oflockout bypass features described above with reference to FIGS. 26-64Bmay also be readily incorporated into or otherwise combined with endeffector (1000). Various suitable ways in which end effector (1000) maybe combined with other teachings herein will be apparent to those ofordinary skill in the art.

IX. Miscellaneous

It should be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.Similarly, those of ordinary skill in the art will recognize thatvarious teachings herein may be readily combined with various teachingsof any of the following: U.S. Pat. No. 5,792,135, entitled “ArticulatedSurgical Instrument For Performing Minimally Invasive Surgery WithEnhanced Dexterity and Sensitivity,” issued Aug. 11, 1998, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.5,817,084, entitled “Remote Center Positioning Device with FlexibleDrive,” issued Oct. 6, 1998, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 5,878,193, entitled “Automated EndoscopeSystem for Optimal Positioning,” issued Mar. 2, 1999, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 6,231,565,entitled “Robotic Arm DLUS for Performing Surgical Tasks,” issued May15, 2001, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool with UltrasoundCauterizing and Cutting Instrument,” issued Aug. 31, 2004, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.6,364,888, entitled “Alignment of Master and Slave in a MinimallyInvasive Surgical Apparatus,” issued Apr. 2, 2002, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 7,524,320,entitled “Mechanical Actuator Interface System for Robotic SurgicalTools,” issued Apr. 28, 2009, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 7,691,098, entitled “Platform Link WristMechanism,” issued Apr. 6, 2010, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 7,806,891, entitled “Repositioningand Reorientation of Master/Slave Relationship in Minimally InvasiveTelesurgery,” issued Oct. 5, 2010, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2013/0012957, entitled“Automated End Effector Component Reloading System for Use with aRobotic System, published Jan. 10, 2013, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2012/0199630, entitled“Robotically-Controlled Surgical Instrument with Force-FeedbackCapabilities,” published Aug. 9, 2012, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2012/0132450, entitled“Shiftable Drive Interface for Robotically-Controlled Surgical Tool,”published May 31, 2012, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0199633, entitled “SurgicalStapling Instruments with Cam-Driven Staple Deployment Arrangements,”published Aug. 9, 2012, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0199631, entitled“Robotically-Controlled Motorized Surgical End Effector System withRotary Actuated Closure Systems Having Variable Actuation Speeds,”published Aug. 9, 2012, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0199632, entitled“Robotically-Controlled Surgical Instrument with SelectivelyArticulatable End Effector,” published Aug. 9, 2012, the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2012/0203247,entitled “Robotically-Controlled Surgical End Effector System,”published Aug. 9, 2012, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0211546, entitled “Drive Interfacefor Operably Coupling a Manipulatable Surgical Tool to a Robot,”published Aug. 23, 2012; U.S. Pub. No. 2012/0138660, entitled“Robotically-Controlled Cable-Based Surgical End Effectors,” publishedJun. 7, 2012, the disclosure of which is incorporated by referenceherein; and/or U.S. Pub. No. 2012/0205421, entitled“Robotically-Controlled Surgical End Effector System with RotaryActuated Closure Systems,” published Aug. 16, 2012, the disclosure ofwhich is incorporated by reference herein.

Versions of the devices described above may be designed to be disposedof after a single use, or they can be designed to be used multipletimes. Versions may, in either or both cases, be reconditioned for reuseafter at least one use. Reconditioning may include any combination ofthe steps of disassembly of the device, followed by cleaning orreplacement of particular pieces, and subsequent reassembly. Inparticular, some versions of the device may be disassembled, and anynumber of the particular pieces or parts of the device may beselectively replaced or removed in any combination. Upon cleaning and/orreplacement of particular parts, some versions of the device may bereassembled for subsequent use either at a reconditioning facility, orby a user immediately prior to a procedure. Those skilled in the artwill appreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

I/We claim:
 1. A method of operating on tissue using a surgicalinstrument, the surgical instrument comprising a body, a shaft assembly,and an end effector, wherein the end effector comprises a lower jawconfigured to receive a staple cartridge, an anvil pivotable toward andaway from the lower jaw, a translatable knife member, and at least onelockout feature, wherein the lockout feature is configured to engage theknife member to thereby prevent translation of the knife member, whereinthe staple cartridge comprises a cartridge body having a bypass feature,wherein the bypass feature is integrally coupled with the cartridgebody, wherein the bypass feature is configured to transition between abypass position and a locked position, wherein the bypass feature isconfigured to prevent engagement of the knife member and the lockoutfeature when in the bypass position, wherein the bypass feature isconfigured to provide for engagement of the knife member and the lockoutfeature when in the locked position, the method comprising the steps of:(a) inserting the staple cartridge into the lower jaw; (b) capturingtissue between the anvil and the staple cartridge; and (c) translatingthe knife member distally from a first proximal position to a firstdistal position, wherein the bypass feature is in the bypass position atthe initiation of the act of translating the knife member distally suchthat the knife member does not engage the lockout feature, wherein theact of translating the knife member distally further comprises: (i)substantially simultaneously cutting the captured tissue and driving aplurality of staples of the staple cartridge through the capturedtissue, and (ii) transitioning the lockout bypass feature from thebypass position to the locked position by engaging the lockout bypassfeature with the knife member.
 2. The method of claim 1, wherein thebypass feature is pivotably coupled with the cartridge body, wherein theact of transitioning the lockout bypass feature from the bypass positionto the locked position comprises pivoting the bypass feature.
 3. Themethod of claim 2, wherein the act of pivoting the bypass featurecomprise pivoting the bypass feature along a laterally extending plane.4. The method of claim 1, wherein the bypass feature is substantiallycompletely disposed within the cartridge when in the bypass position,wherein the bypass feature is at least partially exposed relative to thecartridge when in the locked position.
 5. The method of claim 1, whereinthe cartridge body further comprises a longitudinal channel, wherein actof translating the knife member distally further comprises translatingthe knife member distally within the longitudinal channel.
 6. The methodof claim 5, wherein the bypass feature is at least partially disposedwithin the longitudinal channel when in the locked position.
 7. Themethod of claim 1, wherein the bypass feature is biased toward thelocked position.
 8. The method of claim 7, wherein the staple cartridgefurther comprises a wedge sled, wherein act of translating the knifemember distally further comprises translating the wedge sled distallyfrom a second proximal position to a second distal position.
 9. Themethod of claim 8, wherein the wedge sled is configured to preventmovement of the bypass feature from the bypass position to the lockedposition when in the second proximal position, wherein the wedge sled isconfigured to provide for movement of the bypass feature from the bypassposition to the locked position when in the second distal position. 10.The method of claim 1, wherein the act of transitioning the lockoutbypass feature from the bypass position to the locked position comprisesdeforming the bypass feature.
 11. The method of claim 10, wherein thebypass feature is malleable.
 12. The method of claim 1, furthercomprising translating the knife member proximally from the first distalposition to the first proximal position.
 13. The method of claim 12,wherein the bypass feature remains in the locked position uponcompletion of the act of translating the knife member proximally fromthe first distal position to the first proximal position.
 14. The methodof claim 1, wherein the bypass feature is breakable or cuttable.
 15. Themethod of claim 14, wherein the act of transitioning the lockout bypassfeature from the bypass position to the locked position comprisesbreaking or cutting the bypass feature.
 16. A method of operating ontissue using a surgical instrument, the surgical instrument comprising abody, a shaft assembly, and an end effector, wherein the end effectorcomprises a lower jaw configured to receive a staple cartridge, an anvilpivotable toward and away from the lower jaw, a translatable knifemember, at least one lockout feature, and a bypass feature, wherein thelockout feature is configured to engage the knife member to therebyprevent translation of the knife member, wherein the bypass feature isconfigured to prevent engagement of the knife member and the lockoutfeature, wherein the staple cartridge comprises a cartridge body and awedge sled, the method comprising the steps of: (a) inserting the staplecartridge into the lower jaw; (b) capturing tissue between the anvil andthe staple cartridge; (c) translating the knife member distally a firsttime from a proximal position toward a distal position, wherein the actof translating the knife member distally a first time from a proximalposition toward a distal position further comprises: (i) substantiallysimultaneously cutting the captured tissue and driving a plurality ofstaples of the staple cartridge through the captured tissue, and (ii)engaging the bypass feature with the knife member to thereby preventengagement of the knife member and the lockout feature; and (d)translating the knife member proximally from the distal position back tothe proximal position; wherein the bypass feature remains intact andunchanged during the act of translating the knife member distally afirst time from a proximal position toward a distal position; whereinthe bypass feature further remains unmoved during the act of translatingthe knife member distally a first time from a proximal position toward adistal position.
 17. The method of claim 16, further comprisingtranslating the knife member distally a second time from the proximalposition toward the distal position, wherein the knife member engage thebypass feature as the knife member is driven distally a second time tothereby prevent engagement of the knife member and the lockout feature;wherein the bypass feature remains intact and unchanged during the actof translating the knife member distally a second time from a proximalposition toward a distal position; wherein the bypass feature furtherremains unmoved during the act of translating the knife member distallya second time from a proximal position toward a distal position.
 18. Themethod of claim 16, wherein the bypass feature is integrally coupledwith the cartridge body.
 19. The method of claim 16, wherein thecartridge further comprises a cartridge tray, wherein the bypass featureis integrally coupled with in the cartridge tray.
 20. A method ofoperating on tissue using a surgical instrument, the surgical instrumentcomprising a body, a shaft assembly, and an end effector, wherein theend effector comprises a lower jaw configured to receive a staplecartridge, an anvil pivotable toward and away from the lower jaw, atranslatable knife member, and at least one lockout feature, wherein thelockout feature is configured to engage the knife member to therebyprevent translation of the knife member, wherein the staple cartridgecomprises a cartridge body having a bypass feature, wherein the bypassfeature is integrally coupled with the cartridge body, wherein thebypass feature is configured to transition between a bypass position anda locked position, wherein the bypass feature is configured to preventengagement of the knife member and the lockout feature when in thebypass position, wherein the bypass feature is configured to provide forengagement of the knife member and the lockout feature when in thelocked position, the method comprising the steps of: (a) inserting thestaple cartridge into the lower jaw; (b) capturing tissue between theanvil and the staple cartridge; (c) translating the knife memberdistally from a first proximal position to a first distal position,wherein the bypass feature is in the bypass position at the initiationof the act of translating the knife member distally such that the knifemember does not engage the lockout feature, wherein the act oftranslating the knife member distally further comprises: (i)substantially simultaneously cutting the captured tissue and driving aplurality of staples of the staple cartridge through the capturedtissue, and (ii) transitioning the lockout bypass feature from thebypass position to the locked position by engaging the lockout bypassfeature with the knife member; (d) translating the knife memberproximally from the first distal position to the first proximalposition; and (e) urging the knife member distally after completing theact of translating the knife member proximally, wherein the act ofurging the knife member distally after completing the act of translatingthe knife member proximally comprises engaging the lockout feature,wherein the lockout feature prevents the knife member from reaching thefirst distal position.